Engine Controls - Lacks Power, MIL ON, Various DTC's
21 11 08November 16, 2011
2026771
Vehicle Information
Condition
Engine Lacks Performance, Engine Warning Light ON, DTCs P2563, P2564, P0299 or P20D8 Stored in ECM
Engine does not have any power and the engine warning light may be ON. One of the following DTC entries is stored in the engine control module (ECM).
Vacuum hose kinked, twisted or leaks.
Stud with clamp nut on turbo charger broken/missing, or rotated turbocharger housing. As a result the turbine adjustment travel is outside the tolerance.
Vacuum diaphragm on turbo charger leaks.
Plastic boost pipe from intake side of turbo to intercooler cracked/leaking.
Boost hose connection to intercooler leaking.
Check ECM Software level.
Production Solution
Optimized assembly process to avoid twisted vacuum line.
Increase compressor housing washer thickness.
Change of material for mm. flow adjustment screw.
Improved vacuum diaphragm with charge pressure actuator position sensor -G581-.
Service
Step 1
^ Check the vacuum system for any leaks according to the workshop manual, repair group 21 exhaust/turbo charging, G-charger (section 'Checking Vacuum System').
Tip:
In guided fault finding, in addition to the error codes listed from brand CD 12.83.00, information has been added on possible leaks in the vacuum system.
When checking, observe the following points in particular (Figures 1, 2, and 3):
Hose not inserted into the vacuum container
1.2. Vacuum hose at the solenoid valve, or in the pipe system, is kinked.
^ Re-position hoses to avoid pinching. It is not necessary to replace the hoses.
1.3. Vacuum hose at the solenoid valve, or in the pipe system, is twisted.
^ Re-position hoses to avoid pinching. It is not necessary to replace the hoses.
Step 2
Turbocharger inspection may require the use of a inspection mirror
^ Inspect the turbocharger stud with clamp nut (mm. flow adjustment screw) (Figure 4).
^ Inspect the turbo charger to see whether the stud with clamp nut broken (Figure 5).
^ Inspect the turbo charger to see whether the stud with clamp nut is missing (Figure 6).
If the stud or clamp nut are missing:
Replace turbocharger.
^ Carefully inspect the turbocharger housing around the entire housing assembly for an alignment mark (Figure 7). If the alignment mark is misaligned, this indicates that the housing has rotated.
If misaligned:
Replace turbocharger.
^ Carefully inspect the turbocharger housing around the retaining bolts for witness marks (Figure 8), indicating that the housing has rotated.
If witness marks are present from washers:
Replace turbocharger.
Step 3
^ Disconnect the vacuum hose on the turbo charger vacuum diaphragm.
^ Connect a hand vacuum pump to the vacuum diaphragm and create a vacuum of about 600 mbar.
^ Observe whether the adjusted vacuum is retained.
If the vacuum drops or cannot be achived:
^ Install vacuum diaphragm with charge pressure actuator position sensor -G581- part number 03L198716A according to the repair manual, Group 21 turbo charger, G charger> Removal and installation > Vacuum Diaphragm with Charge Pressure Actuator Position Sensor G581.
If vacuum holds:
And all other vacuum system diagnosis is OK, but fault codes P2563, and/or P2564 are stored in ECM fault memory:
^ Replace the vacuum diaphragm with charge pressure actuator position sensor-G581- part number 03L198716A according to the repair manual, Group 21 turbo charger, G charger> Removal and installation > Vacuum Diaphragm with Charge Pressure Actuator Position Sensor G581.
If vacuum holds:
And all other vacuum system diagnosis is OK, but fault codes P0299, is stored in ECM fault memory:
Continue with diagnosis.
Step 4
^ Inspect the plastic boost pipe that runs from the intake side of the turbocharger to the intercooler for cracks or leaks (Figures 9 and 10).
Step 5
^ Inspect the boost pressure hose connections to the intercooler for leaks.
^ Ensure that the seals are in the proper position and not damaged (Figure 11).
Damaged or missing seals should be replaced. The seals are available separately, it is not necessary to replace the entire hose.
Step 6
^ Ensure that any other Bulletins or Required Vehicle Updates for ECM software updates have been performed. The software programming should be charged to the appropriate bulletin.
Warranty
Required Parts and Tools
Note
Not all parts will be required for each repair.
ONLY USE NECESSARY PARTS.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.