IPD TCV - Help with boost issues

[850Chris]

Until I can get this fixed, do you think I would cause any damage by driving around with the boost sensor disconnected in the short term (from speaking to guys in garage, I believe boost defaults to a pre-determined 'safe' level with sensor disconnected which is different to what I had previously understood where boost will be uncontrolled)?

Reason I ask is that we're away up north at weekend and, if can't use V50, will need to squeeze into my wife's Mazda hatchback.


P.S. Might give this a go http://forums.swedespeed.com/showthr...5-S40-T5/page2

I'll head to dealers and buy replacement part 30677524 (unless anyone knows if I could get one on line).

Will also remove the 'splice' in the TCV to intake line by replacing with a single line - which will require wheel off, a lot of wriggling and much, much swearing!

Finally, will do a another check of all vacuum and boost lines. If none of that solves, then I'll head along to one of the specialists posted above.

[850Chris]

Fault code '6806' logged.

Runs perfect with boost sensor disconnected but I don't want to risk this incase of overboost.

Any ideas given fault code and history described to date?

[SonyVaio]

Here's this from VIDA: ECM-6806 Turbocharger (TC) control system flow fault. Signal too low, B5254T3

Diagnostic trouble code (DTC) information ECM-6806

Condition

The diagnostic trouble code (DTC) is stored if the measured boost pressure from the boost pressure sensor (actual value) is lower or higher than the control module target value (desired value).
The fault is diagnosed by the engine control module (ECM) when the engine speed (RPM) and load are above a certain value.

Reduced boost pressure through full opening of the boost pressure control valve.

Possible source

Signal too high

• The pressure servo for the boost pressure control (BPC) valve is incorrectly adjusted
• Sticking boost pressure control (BPC) valve
• Damaged turbocharger (TC) control valve.

Signal too low

• The hoses between the pressure servo for the boost pressure control (BPC) valve and the turbocharger (TC) control valve have come loose or are blocked or damaged
• The hoses between the turbocharger (TC) control valve and the charge air pipe (between the turbocharger (TC) and the charge air cooler (CAC)) are blocked or damaged
• The pressure servo for the boost pressure control (BPC) valve is incorrectly adjusted
• Damaged boost pressure control (BPC) valve pressure servo
• Sticking boost pressure control (BPC) valve
• Damaged turbocharger (TC) control valve.

Fault symptom[s]

Poor performance.

[850Chris]

Thanks for the info Sony and sorry for my delay in replying. Been away up north over the weekend - took my wife's Mazda 3 in the end which was annoyingly good fun to drive!

Having read your post, if I'm right, this diagnostic code points pretty soundly towards an air leak in the turbo system somewhere (which could be TCV vacuum pipes, charge air pipes or intake pipes). It therefore rules out issue with MAF or fuel system which would throw up another code?

Plan of action now is to re-check TCV vacuum lines a 4th time and definitely get rid of the 'splice' on the intake to TCV line. I'm also thinking I'll ditch the silicone and go back to rubber as one of my mates has a suspicion that the silicone pipes are too soft to use in a vacuum application and therefore may be collapsing as the revs rise? Plausible enough although I believe others have used silicone with no issues (these pipes do seem particularity 'squishy' compared to the rubber ones mind?). This would also tally with the issue persisting when old TCV slotted back in as pipework still the new pipework.

Off work this week so I'll get sorted one way or another, even if it means a visit to the ST/RS specialist in Rosyth (which could be dangerous for the wallet!).

Will keep you posted.

[SonyVaio]

Don't know if you've ruled this out but just come to me.

I take it the IPD kit comes with a wire to extend the original electrical connection for the original TCV??

It may be worth plugging either your original or the IPD TCV straight into the original electrical connection instead of the extended connection (if it exists).

Basically I'm wondering if there is a problem with the extending lead as opposed to the TCV's or silicon hoses.

[850Chris]

IT'S FIXED!!

(Turns out I DID have the blue and red lines reversed. Ooops!!)

Now running like a dream and I am once again a very happy chappy!

Photos of the IPD TCV install on the swedespeed forum are a tad misleading with regards routing of 'red' and 'blue' lines. This is likely in part to the paint marks on the IPD TCV being central and therefore could actually be taken to relate to either nipple depending on which orientation you consider. I'll put up photos of the correct routing in due course so others don't make the same mistake.

[SonyVaio]

Originally Posted by 850Chris

IT'S FIXED!!

(Turns out I DID have the blue and red lines reversed. Ooops!!)

Now running like a dream and I am once again a very happy chappy!

Photos of the IPD TCV install on the swedespeed forum are a tad misleading with regards routing of 'red' and 'blue' lines. This is likely in part to the paint marks on the IPD TCV being central and therefore could actually be taken to relate to either nipple depending on which orientation you consider. I'll put up photos of the correct routing in due course so others don't make the same mistake.

Fantastic news there Chris.

Please take yourself back to your own post #3, read and re-read the fist line and give yourself a hard slap!!



Good to hear the flying machine is back to normal.

[850Chris]

Originally Posted by SonyVaio

Please take yourself back to your own post #3, read and re-read the fist line and give yourself a hard slap!!

I know, I know! Much humble pie has now been eaten!

In my defence, I was working on basis of following picture from swedespeed forum which does seem to indicate pipe from RHS nipple is the one that ports over to turbo compressor nipple (when infact it should go to the intake up behind the CBV)



This misconception was backed up by the following diagram off same website:



Then, through process of elimination, and fact it seemed to be overboosting then shutting the power down, I started thinking that the lines maybe were back to front. A google search (about something not directly related to TCV) threw up this image:



and I had a eureka moment that the intake and turbo lines were actually installed back to front - finally confirmed by this picture



Swapped lines over late last night and problem sorted. Fantastic!

Feels good now but hard to tell if TCV and new intake have made any real difference to power delivery etc...as it was running poor for so long. How it used to be is nothing but a dim and distant memory!

[benyos]

Glad to hear you fixed it but how come it didnt work when you swapped back the oem one?
I have the same symptoms what you had but i couldnt fix yet.
I tried oem tcv, ipd tcv(2 gen) and no luck.

Originally Posted by 850Chris

IT'S FIXED!!

(Turns out I DID have the blue and red lines reversed. Ooops!!)

Now running like a dream and I am once again a very happy chappy!

Photos of the IPD TCV install on the swedespeed forum are a tad misleading with regards routing of 'red' and 'blue' lines. This is likely in part to the paint marks on the IPD TCV being central and therefore could actually be taken to relate to either nipple depending on which orientation you consider. I'll put up photos of the correct routing in due course so others don't make the same mistake.

[SonyVaio]

Originally Posted by benyos

Glad to hear you fixed it but how come it didnt work when you swapped back the oem one?
I have the same symptoms what you had but i couldnt fix yet.
I tried oem tcv, ipd tcv(2 gen) and no luck.

What is the symptoms of your problems?

Loss of power and surging with the T5 can normally be put down to the FPR, it is also worth taking off and cleaning the boost sensor which is located in the RH Front intercooler housing/pipe. Then of course it can be down to the TCV.

If you have replaced the TCV and there is no difference then chances are you're needing to look at the FPR or boost sensor. As Chris found it is easy to get one of the vacuum pipes round the wrong way which can cause all sorts of power delivery issues.

Last but not least, you need to ensure your MAF is functioning correctly and a lot of the above can be deduced from reading any stored codes.

HTH,