vw crafter limp mode and smoking and high revs

[johnjaques]

vw crafter 2.5 tdi 109 56reg lwb 140000 mile on clock
can any one help? first of all ill start with limp mode, well it goes into limp mode with the engine heater coil on, turn the engine off then on all's fine till the next time. ive change the air mass meter and the selionod for the actuator on the turbo but no difference checked the oil and the air filter all fine. now it idles at high revs at 1000 rpm then somthing in the engine department goes plonk (noise)then it goes down to normal revs. ive also cleaned and blocked off the inlet to the egr valve which made no difference, i tryed to get hold of a recon turbo and a actuater but they say this model cant be reconditioned. i have had it on a vag and it come up with turbo under boost. but im stumped as what to do next. and now this morning it started to smoke abit then cleared after a few miles. dont want to take it to vw as they will only guess whats wrong. bin there before many years ago and cost me 1500 qiud for f... all.
any away hope someone can steer me in the write direction.
john

[rayl]

Hi, only a suggestion, might it be the dpf, is the mileage high or do you do a lot of stop start work with little to none motorway travel, i really do hope its not the dpf, may have to have dealer check for dpf blocked,ray

[kenney]

on all 136hk and 164hk engines there has been problems with the turbo there is in fact a recall which is 21D9 Turbos with the following part numbers are not affected 076145701L 076145701K 076145701M 076145701N 076145702A 076145702B 076145701R 076145701P all other turbos are to be replaced FOC if you can find the part number on your turbo you can check and see if the vehicle is affected by the recall or go to a dealer who will help you

[Mawdsy]

I had the same problem with my crafter take it to Vw and tell them the problem I think yours is the same as mine there is a small orange seal on the front of the turbo that perishes and causes limp mode this will be replaced free of charge you may also get a turbo out of them get blagging lol as for your other problems I'm having the exact same and mine came up with an intermittent fault on injector number 5 has your fuel economy gone crap and are you burning more oil than usual ??

[johnjaques]

ok had problem cutting out far to long now so ive taken turbo off and inlet manifold and found that the turbo has been leaking and has end float movment so new one or recon. will clean manifold and dpf out with steam cleaner and clean all the other parts out to. bloody sod of a job getting the turbo of. manifold came of easy after the turbo and needs cleaning as there is a lot of soot and muck in there. turbo part number on the side reads 076145701c / 4937707420 will ring up main dealers on tuesday to see if there was a recall knowing my luck it not. the engine is a bjk 109 on a 56 reg. will keep you updated with new as i go on and i will get to the end of this cutting problem some others and i are getting.john
so to update this post starting with the things i notice as i stripped the components first is the egr : ive taken this of before and it was sooty and sticky black so cleaned refitting (no change still limp mode) this time same as before just not as sticky black stuff. next is dpf i was expecting this to be full and black soot coming out of the back end but to my surpise it was very clean so i will steam clean it anyway, next is the inlet manifold that was thick with black sticky stuff so that is getting a steam for sure, next was the turbo sod to get off but when off there was end float movement and up and down movement so thats got to be a recon or new so far looking on the net its about £500 that could explan the under boost code that its had so this could be the problem, i bloody hope so. just a quick note about the turbo dont try and strip it the bolt will snap of so you will have to drill them all out. i stoped at the first bolt as it snaped of i gave up on that one, not to say that i could of fixed any think in there but just nosey.
picture will follow
well today i ordered the turbo £720 including vat and postage 24 hour from essex turbos bran new oem. not bad i thought.
plus cleaned all pipes and manifold. also cleaned dpf and to my surprize no much soot came out. washed it with a high powered hot wash.

[johnjaques]

kenny ref above

on all 136hk and 164hk engines there has been problems with the turbo there is in fact a recall which is 21D9 Turbos with the following part numbers are not affected 076145701L 076145701K 076145701M 076145701N 076145702A 076145702B 076145701R 076145701P all other turbos are to be replaced FOC if you can find the part number on your turbo you can check and see if the vehicle is affected by the recall or go to a dealer who will help you

(i was told about these turbos and its the oil feed to them that is the problem. no problem with 109 tdi though. no recall.)

[johnjaques]

all done and going much better than before but time will tell as it was intermitant (if it does i will bu n the f--ker) not really. any way to some up the job ive save about 800 900 quid doing the job myself and it was a bit challange but enjoyed it. if you do take on the task after reading this visit my web site www.theflyingporky.co.uk and you can give me a call if you think you need some help over the phone. Im not saying im an expert but i have done it and i could give you a idea on how to do it. if the problem come back i will post it on here lets hope not! anyway good luck if you do decide to have a go. john

[johnjaques]

after 350 miles still going strong