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[P6UL K]

That was an interesting drive home from work...

Left the yard expecting the EML light to come on as per usual as the temperature is pretty cold out and it always comes on after about five minutes into the journey... As expected on it came so while I was on a dead quiet road I just flipped the ignition key back turning the engine off and waitted a couple of seconds then turn on again waiting for the idiot lights to come on then drop the clutch bump starting the car back into life.

EML light extinguished and was already in third gear and the car was feeling quite lively so I accelerated and I could feel the car coming on boost, there was slight hesitation and then BANG  lots of black smoke and the EML light was on again! Managed to limp it to the next petrol station where I popped the bonnet to have a look expecting the worst...

The top boost hose from the intercooler to the inlet had popped off of the intercooler!! Managed to get it back on again as I didn't have any tools on me but then two minutes from home going up a hill it popped off again... So I just limped it home at 10mph and I'll sort it out when I get up in the morning.

I have noticed that on hard revving when the car is stood still that particular boost hose does swell up quite a lot! In fact more than I'd expected it to... Could it be that the EGR valve is not opening and not allowing the boost through thus making the pipes swell as it does?

[Marks DTM Calib]

On the diesel, those pipes do swell a lot!

[P6UL K]

Joff was kind enough to send me his working EGR valve from his 2.2 today, fitted it with that butterfly feeling in my stomach that it 'might' actually fix the problem......

Nope.


Back to the drawing board 

[P6UL K]

The chap on the parts counter at my local WJ Kings Vx dealer has recommended a local garage where 2 ex-Vx technicians have set-up their own business, they both worked at Vx during the lifetime of the Omega and have the 'possible' knowledge I've been looking for to try and overcome this bloody issue!!

Watch this space for either good OR bad news! (Prob the latter lol)

[05omegav6]

It's an Omega... what's the worst that could happen... fingers crossed though, must be doing your bonce in

[Andy H]

Does the 2.2DTi have a mechanical wastegate or is it controlled by the ECU?

Have you cleaned out the intercooler and all the hoses? I'm wondering whether a little pipe to either the wastegate or the MAP (manifold pressure sensor) is blocked causing the ECU to think there is no turbo boost when there is actually enough to blow the inlet hose off

[P6UL K]

1. Does the 2.2DTi have a mechanical wastegate or is it controlled by the ECU?

2. Have you cleaned out the intercooler and all the hoses? I'm wondering whether a little pipe to either the wastegate or the MAP (manifold pressure sensor) is blocked causing the ECU to think there is no turbo boost when there is actually enough to blow the inlet hose off

1. That i couldn't tell you i'm afraid 

2. Intercooler is fairly new, but no i haven't.  All the vacuum pipes are new - as replaced by me not so long ago.

[Marks DTM Calib]

Does the 2.2DTi have a mechanical wastegate or is it controlled by the ECU?

Have you cleaned out the intercooler and all the hoses? I'm wondering whether a little pipe to either the wastegate or the MAP (manifold pressure sensor) is blocked causing the ECU to think there is no turbo boost when there is actually enough to blow the inlet hose off

No waste gate, its a Garret GT1849V which is an early variable vane variant

[Andy H]

Does the 2.2DTi have a mechanical wastegate or is it controlled by the ECU?

Have you cleaned out the intercooler and all the hoses? I'm wondering whether a little pipe to either the wastegate or the MAP (manifold pressure sensor) is blocked causing the ECU to think there is no turbo boost when there is actually enough to blow the inlet hose off

No waste gate, its a Garret GT1849V which is an early variable vane variant

OK.
Is that turbo prone to seized vanes?
Do you know if the vanes are controlled by the ECU? or directly by manifold pressure?

I still think it is worth checking that the ECU is measuring the correct manifold pressure. (and if it is reading right that it isn't getting a delayed reading due to a partial blockage or crap in the sensor)

[Kevin Wood]

Vane actuator is vacuum operated based on an electrical signal from the ECU.

Manifold pressure is reading atmospheric pressure as expected and manually operating the vanes with the engine held at 3,000 RPM gives the correct response at the manifold pressure sensor as expected in the TIS diagnostic procedure.

The whole vacuum system has been tested and found to be working OK.

That said, from the live data I posted earlier in this thread, boost is down on a "working" example of this engine, but the ECU doesn't appear to be modulating the vane actuator to limit boost. Possibly, the actuator is only moving over part of its' travel (although it felt free enough) or another fault is preventing the boost building further.

[henryd]

Vane actuator is vacuum operated based on an electrical signal from the ECU.

Manifold pressure is reading atmospheric pressure as expected and manually operating the vanes with the engine held at 3,000 RPM gives the correct response at the manifold pressure sensor as expected in the TIS diagnostic procedure.

The whole vacuum system has been tested and found to be working OK.

That said, from the live data I posted earlier in this thread, boost is down on a "working" example of this engine, but the ECU doesn't appear to be modulating the vane actuator to limit boost. Possibly, the actuator is only moving over part of its' travel (although it felt free enough) or another fault is preventing the boost building further.

I still think the turbo is the problem,saw similar on an A4 Pd a few years back,supposedly new(reman) turbo but similar symptoms to this one,a new turbo fixed it

[P6UL K]

Vane actuator is vacuum operated based on an electrical signal from the ECU.

Manifold pressure is reading atmospheric pressure as expected and manually operating the vanes with the engine held at 3,000 RPM gives the correct response at the manifold pressure sensor as expected in the TIS diagnostic procedure.

The whole vacuum system has been tested and found to be working OK.

That said, from the live data I posted earlier in this thread, boost is down on a "working" example of this engine, but the ECU doesn't appear to be modulating the vane actuator to limit boost. Possibly, the actuator is only moving over part of its' travel (although it felt free enough) or another fault is preventing the boost building further.

I still think the turbo is the problem,saw similar on an A4 Pd a few years back,supposedly new(reman) turbo but similar symptoms to this one,a new turbo fixed it

As already said Henry, the Turbo is a new/recon unit.

[henryd]

Vane actuator is vacuum operated based on an electrical signal from the ECU.

Manifold pressure is reading atmospheric pressure as expected and manually operating the vanes with the engine held at 3,000 RPM gives the correct response at the manifold pressure sensor as expected in the TIS diagnostic procedure.

The whole vacuum system has been tested and found to be working OK.

That said, from the live data I posted earlier in this thread, boost is down on a "working" example of this engine, but the ECU doesn't appear to be modulating the vane actuator to limit boost. Possibly, the actuator is only moving over part of its' travel (although it felt free enough) or another fault is preventing the boost building further.

I still think the turbo is the problem,saw similar on an A4 Pd a few years back,supposedly new(reman) turbo but similar symptoms to this one,a new turbo fixed it

As already said Henry, the Turbo is a new/recon unit.

As was the one on the A4,shame no-one has one that you could try

[swordfish]

i got one , don't forget 

[P6UL K]

i got one , don't forget 

See what this Vx garage says chap and I'll go from there?