Service Issues: Two error messages - car in limp mode

[ilysampson]

Originally Posted by ilysampson

hi
new to this forum, as just got rid of disco 3 for xc90, sounds like i need to also disconect the resistor as i have the same problem, i know this will be a temporary fix, but will do until i can get the main problem fixed, greatly appreciated if you could tell me where to find it and is it just a case of disconecting,

cheers richard

think i just found it, as it caught fire before fuse 11 blew, good start to sunday morning, lol

after my little fire incident, had no choice but take to main dealer in maidenhead which is walking distance, £228 to replace hose that contains resistor, could of been worse hopefully that's it sorted, will know tomorrow

[mikepday]

Hi, Have had the same issue with my V70, problems with codes and limp mode, changed EGR controller/governor solenoid and all seemed well, until small fire in the PTC sensor a couple of days later and fuse 11 blown again for the umpteenth time.

Looks like the sensor is not available as a separate unit anymore but comes as part of the Fresh air inlet hose to the turbo......£68 + VAT one on order for the morning hope it cures it this time, should be a ten minute fix.

Any one had any luck finding these as a VW/Audi part nuumber separately? As its an AUDI engine.

Mike.

[paul chocks]

Don't know about vw/Audi part number. Is it an Audi engine then?

I replaced the whole hose too - I thinks just the sensor was available back when I had the issue, but I couldn't remove it from the hose. Don't know if it was stick or not. Hose change was Ok, but a little fiddly behind the high engine on an XC90.

Good luck.

(interestingly, I also have an Audi which every once in a while goes into limp mode too. So far, just unplugging the similar sensor and resetting it clears the fault)

[TruckbusUK]

Originally Posted by mikepday

Any one had any luck finding these as a VW/Audi part nuumber separately? As its an AUDI engine.

Mike.

Not entirely sure which engine we are talking about here but as far as I'm aware the Volvo D5 D5244xx engines are not AUDI units, they are Volvo in-house developed engines.

I'd agree, in the early 80's both Audi and Volvo developed the use of 5-cylinder engines, but I'm pretty sure they never shared the technology.

Maybe the resistor in this case is a common part shared by many manufactures, probably more linked to the manufacturer that developed the turbo or EGR control systems.

[guestinlancs]

So reading the threads, there seems to be a common fault with the sensor located on the side of the intake hose to the Turbo...I've a mare of a job trying to locate problem that keeps my motor (130k) to more than around 2000rpm - constant limp. Message lights say Engine Service and High Emissions Service required. Codes read Faulty ERG (stripped and cleaned to new and shiny) Faulty Turbo Nozzle (ever tried to get a turbo off an AWD XC90? - not even going to try). isoftcar reader also located the same 2 fuses as above, climate and glow plugs. They're both 60 am located beneath the main fuse box (thanks to this forum for explaining how to get to them!). I've ordered a few spare fuses but reading all the good stuff above, seems like they'll pop again. Up to now I've changed Turbo pressure Selenoid, Maff (for good measure), Fuel Rail Pressure Sensor, removed and cleaned (from a fairly solidly blocked state), even got some decarboniser in through the exhaust manifold. Engine starts and sounds great, but won't climb above just over 2000 revs before wanting to kick-down. done a few hundred miles like this, hoping it might improve during a daily (slow) motorway commute - no luck, so makes sense to take a punt on the hose/sensor. I'll return with findings soon.

[SwissXC90]

Originally Posted by guestinlancs

I've a mare of a job trying to locate problem that keeps my motor (130k) to more than around 2000rpm - constant limp. Message lights say Engine Service and High Emissions Service required. Codes read Faulty ERG (stripped and cleaned to new and shiny) Faulty Turbo Nozzle (ever tried to get a turbo off an AWD XC90? - not even going to try).

Getting the turbo off, inspecting it, and cleaning it so that the variable vanes work again is your next step

Or start using VIDA and monitoring all values to see what is going wrong at 2000 RPM (which is where the turbo kicks in)

[Zebster]

Is there a stored OBD2 code that points to this sensor being faulty?

[guestinlancs]

Originally Posted by SwissXC90

Getting the turbo off, inspecting it, and cleaning it so that the variable vanes work again is your next step

Or start using VIDA and monitoring all values to see what is going wrong at 2000 RPM (which is where the turbo kicks in)

Thanks SwissXC90
Ordered a PCT and new plastic charge pipe. Carbonised variable vanes are my suspicion, especially after cleaning what had become a solid with soot EGR but reading all above, and considering I'm getting the same blown climate and glow plug 60amp fuses I thought I'd try the PCT before the Turbo. Problem is, I'll be sending the car to the garage for the Turbo work - big £'s no doubt!

[guestinlancs]

Originally Posted by Zebster

Is there a stored OBD2 code that points to this sensor being faulty?

Thanks Zebster - My icarsoft reader is reporting ECM-6800 Variable Nozzle Turbo Governor and ECM-4400 EGR Valve, but I stripped, cleaned and refitted the latter and still get codes even after wipe of stored codes. The other two messages are ECM-6000 Air Con A/C Relay and ECM6600 Glow Plug Relay; same as mentioned along with PCT in earlier in this string. I've got 60am fuses coming for replacement but expect, it I don't sort other problems, that these will just keep blowing or worse, the PCT will catch fire as described above.

[SwissXC90]

Originally Posted by guestinlancs

Thanks SwissXC90
Ordered a PCT and new plastic charge pipe. Carbonised variable vanes are my suspicion, especially after cleaning what had become a solid with soot EGR but reading all above, and considering I'm getting the same blown climate and glow plug 60amp fuses I thought I'd try the PCT before the Turbo. Problem is, I'll be sending the car to the garage for the Turbo work - big £'s no doubt!

OK, it takes a HUGE amount of current and power to blow a 60A fuse
That's 720 watts of electrical energy to blow that baby

You need to be looking for a wire loom short or something really drastic that is sucking so much power.
It should be really obvious.
60A fuses don't just blow for no discernable reason.

And as for the turbo, yes: all the soot in the EGR went through the turbo, and thus the chances of vanes sticking are quite high.