Help with 2 Engine Faults Please

[vk]

Hi everyone,

Am having trouble with my 2009 GT Sport TDI, the car has a 42DD intake & MAF de-grid, bluefin tune, and recently a straight pipe from the DPF back (removed the res and muffler).

Since doing the exhaust, I have been having a squiggly light popup, (had it once before), however the past week it has been coming up every single drive.

I just ran a scan with VCDS and came up with the following two faults on the engine, could anyone shed some light on these or do I need to go to a mechanic? (if so can anyone recommend someone that knows what they are doing on VW diesels in Melbourne?)

Address 01: Engine        Labels: 03G-906-018-BMN.clb
   Part No SW: 03G 906 018 FC    HW: 03G 906 018 FC
   Component: R4 2.0l PPD1.2 G    1879  
   Revision: --H52---    Serial number: VWX7Z0H23NVXXX
   Coding: 0000078
   Shop #: WSC 06441 785 00200
   VCID: 6BFB1A5C4A683B190A-803E

2 Faults Found:
005214 - Mass Air Flow during Regeneration too Low 
               P145E - 006 -  - Intermittent
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 5
                    Fault Frequency: 4
                    Reset counter: 38
                    Mileage: 140XXX km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 00:34:34

             Freeze Frame:
                    RPM: 2080 /min
                    Torque: 32.0 Nm
                    Speed: 105.0 km/h
                        0.00 %
                        11.31 %
                    Mass Air / Rev.: 321.6 mg/str
                    Mass Air / Rev.: 594.1 mg/str

012600 - Intake Manifold Runner Control 
               P3138 - 006 - Regulation Deviation - Intermittent - MIL ON
             Freeze Frame:
                    Fault Status: 10100001
                    Fault Priority: 5
                    Fault Frequency: 5
                    Reset counter: 40
                    Mileage: 140XXX km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 17:24:12

             Freeze Frame:
                    RPM: 2496 /min
                    Torque: 96.0 Nm
                    Speed: 97.0 km/h
                    Mass Air / Rev.: 436.0 mg/str
                    Mass Air / Rev.: 583.1 mg/str
                    Lambda: -21.9 %
                    Text: Kein Messwert verfuegbar

Readiness: N/A

[Greg Roles]

The problem is your car is trying to do a DPF regen and one of the flaps is preventing it from doing so.

I had the first error when I removed the EGR valve, which needs to partially close during regens. Similarly there are flaps in the intake runners, and the second error would suggest they are playing up, perhaps they need to be in a set position for a regen as well. I'd check the diaphram on the left side ( facing engine ) on the intake manifold, and the rubber pipe to and from, but so too the solenoid controlling this could be cactus, it's an odd problem.

Bottom line you have to get that sorted so the car can regen, if the coil is showing up each drive then you are at or above 60% clogged in the DPF and once you hit 80% the car will go into limp mode, and totally refuse to start at 90%.

Afraid I can't recommend a VAG specialist in Melbourne, but I'm sure there is someone nearby. The other real possibility is the EGR / runner flaps are simply sticking due to EGR/soot buildup, have you ever cleaned out the upper intake with the diesel specific spray from supercheap? THAT would be a great idea right now.....

Also even with the flaps playing up you can successfully do a regen if you can find a place to keep the car under load as muich as possible. I could do regens without the EGR so long as I never backed off much, in that I always kept the car sublty accelerating on the highhway or somewhere else where you don't have to slow down much. It;s not about speeding, more about keeping the time spent off the throttle as low as possible. It's tricky, but doable, but next to impossible in traffic / lights etc.

[Greg Roles]

Check the engine measuring block 075, 070 and 068 to see where the DPF is at.

[vk]

So it WAS what Greg said above , unfortunately two of the flaps in my inlet manifold had given way. I had to replace the entire manifold, and because I sourced a brand new one it was not cheap unfortunately. Also, the GT TDI has a very particular manifold that is only found on two cars of that year I think.

The old manifold was completely clogged up inside too, the mechanic asked if I had a heavy foot, and I said maybe, and he then said that it must have been the previous owner that didn't give it enough boot to flush it out.

Some pics:

[gldgti]

can you clean thata one up and keep it as a spare? or sell it?

[Greg Roles]

My question is did you get all the flap parts out?? It's an odd problem, but glad you got it fixed.

[Ryeman]

Pardon my ignorance
In thought diesels didn't have flaps but were controlled by fuel feed only........or is that non turbo ones?.

[gldgti]

Pardon my ignorance
In thought diesels didn't have flaps but were controlled by fuel feed only........or is that non turbo ones?.

those modify the flow path through the intake manifold to change the turbulence of the incoming air at different engine speeds, to help with complete combustion

[Greg Roles]

Diesels donlt have a flap to control air for throttle purposes, just one for EGR introduction, and these ones close and open the second inlet port at various RPM's as gldgti mentions above. They are also important in the DPF regen cycle. The EGR flap also helps stop the car smoothly on key off, so it doesn't "run on" a bit.

[vk]

can you clean thata one up and keep it as a spare? or sell it?

I feel a bit stupid because they made it seem like it was useless now and I left it there

Also I just found this, P2015 error fix for Common Rail TDI I wonder if that is a solution?