Case Study: 15202 - Actuator Module for Turbocharger 1 P00AF 00 [109] - Stuck

[golfi_vend]

14846 - Turbocharger Boost Control Position Sensor Circuit 
          P2563 00 [096] - Implausible Signal
          Intermittent - Not Confirmed - Tested Since Memory Clear

15202 - Actuator Module for Turbocharger 1 
          P00AF 00 [109] - Stuck
          Confirmed - Tested Since Memory Clear

Issue here was, that customer went to dealer as warranty has just ran out. Dealer suggested new turbocharger to be fitted.
He then came to us by hearing we might have other solution.

At initial diagnostic we confirmed the same thing that waste gate doesn't move. My thought was that it must have similar issue to 1.2-1.4 engines waste gate rod getting seized.
Read here: https://forums.ross-tech.com/showth...t-TSI-MK7-Golf&p=106771&viewfull=1#post106771 and here: https://www.golfmk7.com/forums/showthread.php?t=28690

It was not possible to remove circlip just from underneath the car and we suggested removing the turbocharger to have better access.
While starting the removal process it became clear that circlip can be easily accessed if right driveshaft and catalytic converter are removed.
Circlip removal was easy, removing spindle wasn't, as it was seized pretty good. Using heat and lot of patience it gave up and was finally removed.


Left to do here was only to clean spindle really good, reinstall it with good grease and assemble everything else.
Using output test of VCDS showed good movement of spindle and rod with no resistance what-so-ever.

Most of the credit goes to my good co-worker Roland who didn't gave up and fixed this issue for customer.
I believe this issue might be happening on all EA888 engines... .






And autoscan for reference.

Friday,16,August,2019,08:59:03:39429
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 19.6.1.0 (x64)  HEX-NET CB: 0.4508.4
Data version: 20190529 DS308.0
www.Ross-Tech.com

Dealer/Shop Name: Tarfor OÜ

VIN: TMBJE9NE8E0   License Plate: 
Mileage: 101350km-62975mi   Repair Order: 



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: NE-SK37 (5Q0)
Scan: 01 03 08 09 10 15 16 17 19 42 44 52 55 5F 69 A9

VIN: TMBJE9NE8E0   Mileage: 101350km-62975miles

01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
10-Park/Steer Assist -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
55-Headlight Range -- Status: OK 0000
5F-Information Electr. -- Status: OK 0000
69-Trailer -- Status: OK 0000
A9-Struct. Borne Sound -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine (J623-CHHB)       Labels:. 06K-907-425-V1.clb
   Part No SW: 5G0 906 259     HW: 06K 907 425 B
   Component: 2.0l R4 TFSI  H13 0007  
   Revision: --H13---    
   Coding: 0C1900322434010B0000
   Shop #: WSC 73430 031 00133
   ASAM Dataset: EV_ECM20TFS0215G0906259 001011
   ROD: EV_ECM20TFS0215G0906259.rod
   VCID: EB96BF86021F7517DC-80BE

2 Faults Found:
14846 - Turbocharger Boost Control Position Sensor Circuit 
          P2563 00 [096] - Implausible Signal
          Intermittent - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 101069 km
                    Date: 2019.08.09
                    Time: 11:09:33

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 2 km/h
                    Coolant temperature: 45 °C
                    Intake air temperature: 27 °C
                    Ambient air pressure: 1000 mbar
                    Voltage terminal 30: 10.000 V
                    Unlearning counter according OBD: 28
                    Status of charge air pressure control valve basic setting-LV_BPA_AD_REQ[0]: 00000001 
                    Charge air pressure control valve uncond voltage sensor: 2.5342 V
                    Charge air pressure control valve position: target value: 0.00 %
                    Charge air pressure control valve position: actual value: 23.84 %
                    Charge air pressure control valve activation pulse duty factor: -35.94 %
                    Charge air pressure control valve voltage: position closed: 3.2474 V
                    STATE_BPA[0]: AD

15202 - Actuator Module for Turbocharger 1 
          P00AF 00 [109] - Stuck
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 8
                    Mileage: 101069 km
                    Date: 2019.08.09
                    Time: 11:09:00

                    Engine speed: 2571.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 23 km/h
                    Coolant temperature: 36 °C
                    Intake air temperature: 25 °C
                    Ambient air pressure: 1000 mbar
                    Voltage terminal 30: 14.531 V
                    Unlearning counter according OBD: 40
                    Status of charge air pressure control valve basic setting-LV_BPA_AD_REQ[0]: 00000000 
                    Charge air pressure control valve uncond voltage sensor: 1.7676 V
                    Charge air pressure control valve position: target value: 89.24 %
                    Charge air pressure control valve position: actual value: 49.32 %
                    Charge air pressure control valve activation pulse duty factor: 77.41 %
                    Charge air pressure control valve voltage: position closed: 3.2474 V
                    STATE_BPA[0]: OPM

Readiness: 0000 0000

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels: 5Q0-907-379-ESP-V1.clb
   Part No SW: 5Q0 907 379 R    HW: 5Q0 907 379 F
   Component: EMB8 EHCB     H31 0356  
   Revision: 00000000    Serial number: 61124000000A4A
   Coding: 1C076B915422296F007D060941CA2938D62A9400608294F600400070C009
   Shop #: WSC 73430 031 00063
   ASAM Dataset: EV_Brake1UDSContiMK100ESP 033001
   ROD: EV_Brake1UDSContiMK100ESP_033_VW37.rod
   VCID: CBD61F06625F9517BC-809E

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J255)       Labels:| 5G0-907-044.clb
   Part No SW: 5E0 907 044 N    HW: 5E0 907 044 N
   Component: Climatronic   H03 0907  
   Revision: 00001K06    
   Coding: 02010004000100011005000100100000
   Shop #: WSC 73430 031 00063
   ASAM Dataset: EV_ACClimaBHBVW37X 003017
   ROD: EV_ACClimaBHBVW37X_003_VW37.rod
   VCID: B02C68EAEBB9D6CFA9-80E4

   Fresh Air Blower Front: 

   Geber für Kältemitteldruck/Kältemitteltemperatur: 

   Air quality sensor: 

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:| 5Q0-937-08X-HV1.clb
   Part No SW: 5Q0 937 086 Q    HW: 5Q0 937 086 Q
   Component: BCM PQ37BOSCH 026 0097  
   Revision: --------    Serial number: 86580205141019
   Coding: 0C020A66C24722FB07A04082B11C07280000000000000000000000000000
   Shop #: WSC 73430 790 00133
   ASAM Dataset: EV_BodyContrModul1UDSBosc 012003
   ROD: EV_BCMBOSCH_012.rod
   VCID: C8DC200A73297E0F91-809C

   Control Unit For Wiper Motor: 
   Subsystem 1 - Part No SW: 5E1 955 119     HW: 5E1 955 119   Labels: 5QX-955-119-V1.CLB
   Component: WWS371 140415  041 0570 
   Serial number:         140424090521
   Coding: 065DDD

   Rain Light Recognition Sensor: 
   Subsystem 2 - Part No SW: 5Q0 955 547     HW: 5Q0 955 547   Labels: 5Q0-955-547.CLB
   Component: RLFS  024 0042 
   Serial number: Y14M05D07H05M46S30S8
   Coding: 02805D

   Sensor For Anti Theft Alarm System: 
   Subsystem 3 - Part No SW: 5Q0 951 171     HW: 5Q0 951 171 
   Component: Sensor, DWA  005 0315 
   Serial number: 000000000ZY140511W06

   Alarm horn: 
   Subsystem 4 - Part No SW: 5Q0 951 605     HW: 5Q0 951 605 
   Component: Sirene, DWA  004 0311 
   Serial number: 00000000000059363646

   Relative Air Humidity Interior Sender: 

No fault code found.

-------------------------------------------------------------------------------
Address 10: Park/Steer Assist (J791)       Labels:| 5Q0-919-283.clb
   Part No SW: 5Q0 919 283 B    HW: 5Q0 919 283 
   Component: PARKHILFE 4K  H09 0033  
   Revision: --------    Serial number: 60831411900727
   Coding: 0001050101
   Shop #: WSC 73430 031 00063
   ASAM Dataset: EV_EPHVA14AU3700000 002018
   ROD: EV_EPHVA14AU3700000_002_VW37.rod
   VCID: B83C50CA03C90E8FE1-80EC

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 5Q0-959-655.clb
   Part No SW: 3Q0 959 655 AB    HW: 3Q0 959 655 AB
   Component: Airbag VW20   012 0189  
   Revision: --------    Serial number: 003P3P2QMLNL
   Coding: 98FCC000000000005C5400CC000800000065
   Shop #: WSC 73430 790 00133
   ASAM Dataset: EV_AirbaVW20TS6VW48X 001116
   ROD: EV_AirbaVW20TS6VW48X.rod
   VCID: FEB086D2616DF0BF6B-80AA

   Side Sensor Driver Front: 
   Subsystem 1 - Part No SW: -----------    HW: 454 002 204 14
   Component: SideSensor_Df  008 0887 
   Serial number: 3576U0000008C890AF0R
   Coding: 2D2D2D

   Side Sensor Passenger Front: 
   Subsystem 2 - Part No SW: -----------    HW: 454 001 904 14
   Component: SideSensor_Pf  008 0887 
   Serial number: 3586U000000B6D796F0X
   Coding: 2D2D2D

   Side Sensor Driver Rear: 
   Subsystem 3 - Part No SW: -----------    HW: 454 802 004 14
   Component: SideSensor_Dr  111 0148 
   Serial number: 3516RA5D863030000004
   Coding: 2D2D2D

   Side Sensor Passenger Rear: 
   Subsystem 4 - Part No SW: -----------    HW: 454 802 004 14
   Component: SideSensor_Pr  111 0148 
   Serial number: 3526RC3EA8503000000C
   Coding: 2D2D2D

   Front Sensor Driver: 
   Subsystem 5 - Part No SW: -----------    HW: 454 801 903 14
   Component: FrontSensor_D  114 0149 
   Serial number: 3556VE57A2D03000000I
   Coding: 2D2D2D

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel (J527)       Labels:| 5Q0-953-549.clb
   Part No SW: 5Q0 953 507 AC    HW: 5Q0 953 549 
   Component: Lenks. Modul  007 0070  
   Revision: --------    Serial number: 30041404400743
   Coding: 1400
   Shop #: WSC 73430 031 00063
   ASAM Dataset: EV_SMLSKLOMQB 009001
   ROD: EV_SMLSKLOMQB_020_VW37.rod
   VCID: F7BE93F64E57C1F728-80A2

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:| 5G0-920-XXX-17.clb-SRI3
   Part No SW: 5E0 920 871 C    HW: 5E0 920 871 C
   Component: KOMBI         333 2210  
   Coding: 07A509002980000801082A00000000
   Shop #: WSC 73430 031 00133
   ASAM Dataset: EV_DashBoardVDDMQBAB 008031
   ROD: EV_DashBoardVDDMQBAB_008_VW37.rod
   VCID: A81C808AD3699E0F71-80FC

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:| 5Q0-907-530-V1.clb
   Part No SW: 5Q0 907 530 Q    HW: 5Q0 907 530 F
   Component: GW MQB High   125 1164  
   Revision: --------    Serial number: 0001924458
   Coding: 030100342F085900EF00026A080F00010001050000000000000000000000
   Shop #: WSC 73430 790 00133
   ASAM Dataset: EV_GatewLear 010015
   ROD: EV_GatewLear_010.rod
   VCID: BFCE3BD626E739B720-80EA

   Alternator: 

   Multi Function Steering Wheel Control Module: 
   Subsystem 2 - Part No SW: 5E0 919 719 A    HW: 5E0 919 719 A
   Component: E221__MFL-PR6  H04 0130 
   Serial number: 000000000B1229250414

   Battery Monitoring Control Module: 
   Subsystem 3 - Part No SW: 5Q0 915 181 E    HW: 5Q0 915 181 E
   Component: J367-BDMHella  H03 8043 
   Serial number: 6463323203          

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver (J386)       Labels:| 5QX-959-X93-42.clb
   Part No SW: 5Q4 959 593 B    HW: 5Q4 959 593 B
   Component: TSG FS        009 0014  
   Serial number: 0000101630324 
   Coding: 001D0020D000040000001100
   Shop #: WSC 73430 790 00133
   ASAM Dataset: EV_DCUDriveSideEWMAXCONT 006001
   ROD: EV_DCUDriveSideEWMAXCONT.rod
   VCID: C4C4343A4F015A6F7D-8090

   Drivers Door Rear Control Module: 
   Subsystem 1 - Part No SW: 5Q0 959 811 A    HW: 5Q0 959 811 A  Labels: 5QX-959-81X-V1.CLB
   Component: FOND_FHSG_DRV  005 0005 
   Serial number: 00000000000002520980
   Coding: 010200

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist (J500)       Labels:| 5Q0-909-144.clb
   Part No SW: 3Q0 909 144 F    HW: 3Q0 909 144 F
   Component: EPS_MQB_ZFLS  503 5043  
   Coding: 8103
   Shop #: WSC 73430 790 00133
   ASAM Dataset: EV_SteerAssisMQB 010031
   ROD: EV_SteerAssisMQB_010.rod
   VCID: B52259FE14DBF3E7FA-80E0

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. (J387)       Labels:| 5QX-959-X92-52.clb
   Part No SW: 5Q4 959 592 B    HW: 5Q4 959 592 B
   Component: TSG BFS       009 0014  
   Serial number: 0000101598853 
   Coding: 001D0020D000040000001100
   Shop #: WSC 73430 790 00133
   ASAM Dataset: EV_DCUPasseSideEWMAXCONT 006001
   ROD: EV_DCUPasseSideEWMAXCONT.rod
   VCID: C3C637264A0F5D5744-8096

   Passengers Rear Door Control Module: 
   Subsystem 1 - Part No SW: 5Q0 959 812 A    HW: 5Q0 959 812 A  Labels: 5QX-959-81X-V1.CLB
   Component: FOND_FHSG_PSG  005 0005 
   Serial number: 00000000000002480637
   Coding: 190200

No fault code found.

-------------------------------------------------------------------------------
Address 55: Headlight Range (J745)       Labels:| 7P6-907-357.clb
   Part No SW: 7P6 907 357 D    HW: 7P6 907 357 A
   Component: AFS-ECU       H07 0090  
   Revision: --------    Serial number: --------------
   Coding: 03DA02003F000000
   Shop #: WSC 73430 790 00063
   ASAM Dataset: EV_HeadlRegulVWAFSMQB 001120
   ROD: EV_HeadlRegulVWAFSMQB.rod
   VCID: C0CC382A5B19464F59-8094

   Left Headlamp Power Output Stage: 
   Subsystem 1 - Part No SW: 1T0 941 329 B    HW: 1T0 941 329 B  Labels: 3D0-941-329.CLB
   Component: LeiMo links  H06 0009 
   Coding: 3E0000

   Right Headlamp Power Output Stage: 
   Subsystem 2 - Part No SW: 1T0 941 329 B    HW: 1T0 941 329 B  Labels: 3D0-941-329.CLB
   Component: LeiMo rechts  H06 0009 
   Coding: 3E0000

No fault code found.

-------------------------------------------------------------------------------
Address 5F: Information Electr. (J794)       Labels:| 5E0-035-MIB-STD1.clb
   Part No SW: 5E0 035 840 A    HW: 5E0 035 840 A
   Component: MU-S--ER      040 0490  
   Serial number: S3E00405140572
   Coding: 037352000000000011110002000100002F0001A40100010000
   Shop #: WSC 131071 1023 2097151
   ASAM Dataset: EV_MUStd4CPASE 002039
   ROD: EV_MUStd4CPASE_VW37.rod
   VCID: 9F0E9B56862759B700-80CA

   Operating And Display Unit 1: 
   Subsystem 1 - Part No SW: 5E0 919 605 B    HW: 5E0 919 605 B
   Component: ABT_Std_Plus  H50 0022 
   Serial number: SKZ8Z9PK60150S      

No fault code found.

-------------------------------------------------------------------------------
Address 69: Trailer (J345)       Labels:| 5Q0-907-383.clb
   Part No SW: 5Q0 907 383     HW: 5Q0 907 383 
   Component: Anhaenger     H11 0030  
   Revision: 6A001003    Serial number: 00008200286511
   Coding: 0100000200000000
   Shop #: WSC 73430 790 00133
   ASAM Dataset: EV_TrailFunctDemouHella 001001
   ROD: EV_TrailFunctDemouHella.rod
   VCID: F4A4A4FA5F21AAEF0D-80A0

No fault code found.

-------------------------------------------------------------------------------
Address A9: Struct. Borne Sound (J869)       Labels: 4H0-907-159.clb
   Part No SW: 5E0 907 159     HW: 4H0 907 159 A
   Component: SAS-GEN 2     H06 0001  
   Serial number: 140331200219
   ASAM Dataset: EV_SoundActuaGen2AU64X 003010
   ROD: EV_SoundActuaGen2AU64X.rod
   VCID: E99AC58E08E36707AE-80BC

No fault code found.

End----(Elapsed Time: 01:40, VBatt start/end: 11.8V/11.7V. VIgn 11.7V)-----

 

[Jef]

As per forum rules, #8:

 

[Jack@European_Parts]

Reaming hole and using a high heat never seize from Wurth & with copper might work better than grease.

 

[Danners74]

Hot bolt paste...….ive done a few.

 

[Placeborick]

Yep, this has been happening on my 65' tts. Manually pulling the arm back and forth seems to fix the problem temporarily.
Until i can get in there and give it a proper service anyway.

 

[PetrolDave]

Yep, this has been happening on my 65' tts.

NB - most people on here are not from the UK so don't understand UK number plates, so saying 65' won't mean anything to them, always best to quote the model year (note NOT year of registration, that's not the same thing).

UK 65 plate = registered between September 2015 and February 2016, so probably (but not definitely as the dealer could have had it in stock) a 2016 MY vehicle.

 

[Fred's Imports]

First post here, might be my last.

I just want to explain to everyone on the forum here who owns a shop for a living that this Obamatized repair is for those who don't have money to remove or replace the turbocharger properly.

4 hours now, FOUR EFFING HOURS wasted time to try and patch up a turbo that only costs me $700 dollars US.

Those of you trying to save customers money usually end up plugging tires in the sidewall and doing the job all over again in short order.

Thank-you for me venting on you, my purge valve leaketh badly.

 

[Jef]

As per every financial advisor out there:

past performance does not predict future returns

 

[Fred's Imports]

On the new turbocharger that pin is NOT removable without it being pressed out. So much for the copper paste theory.

 

[mecjp2216]

Same case yesterday after fixed the pin problem erase code perfom adaptation g581 the code return only p2563
My car golf 2015 cxbb 1.8l
Whats happen ????

 

[Rich]

I have the turbo on the car (2017 GTI-73,000mi.), the circlip is removed and the clevis pin does not come out. Is it pressed in on this car? I have been heating it up to no avail. If I take the turbo off, then I will replace it since it would be off. It's been a real battle. Too many nuts and bolts in bad shape.

 

[golfi_vend]

First post here, might be my last.

I just want to explain to everyone on the forum here who owns a shop for a living that this Obamatized repair is for those who don't have money to remove or replace the turbocharger properly.

4 hours now, FOUR EFFING HOURS wasted time to try and patch up a turbo that only costs me $700 dollars US.

Those of you trying to save customers money usually end up plugging tires in the sidewall and doing the job all over again in short order.

Thank-you for me venting on you, my purge valve leaketh badly.

Hehe, Years later I discovered this message.

As You can see as I wrote we investigated the issue. Initial thought was to remove Turbo and inspect further. As it became clear that pin can be removed without and without damage to Turbo, this route was chosen.
It never wasn't "let's try to cut every corner available"

Spoiler

Also You must realise that not parts of the World are not US. Our prices for parts and specially cars aren't low as it is for You guys.(Just for bad example: iPhone 799USD vs 989EUR). Same goes for prices for cars.

 

[Uwe]

Our prices for parts and specially cars aren't low as it is for You guys.(Just for bad example: iPhone 799USD vs 989EUR). Same goes for prices for cars.

Much of that difference is the crazy VAT taxes that you guys have. We don't have those here at all. We do have Sales Taxes in many states, but they tend to be around 6-8%, not 20%+, and prices are always shown without Sales Tax.

-Uwe-