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[P6UL K]

Mum bus, eh?

As said, I have a log from a good one and a broken one, albeit a 2.2, if you need them.

And is still not fixed.... Now on eBay as 'Spares or Repair'

I've exhausted all avenues and with no-one seemingly having the necessary genuine experience on these engines I've thrown the towel in 

[TheBoy]

They are not the,best engine to have in a zafira,only 100 bhp and,not very quick,remap might help tho,but why not stick a,v6 in it ....

I'd be content with 100bhp in it. Given that it tops out at about 80mph, I'm guessing its got about half of that...

[Marks DTM Calib]

As we now know the Turbo is boosting (at least without load) well, I would be checking:

1) All solenoids by bypassing them all at the same time (thought being that if a single solenoid is faulty or leaking vac, it would not show up on the test we did but might affect the operation is a second is then enabled). This probably requries the turbo and swirl flaps actuators needing a direct supply and the EGR getting no supply.

2) Intercooler to inlet pipe - its the only one we didn't remove so wants checking, I would also liked to have removed and pressure tested the intercooler but as you know, it would not come out easily.

[Kevin Wood]

How much boost pressure are you seeing under load?

P6ULK's was vaguely tracking a little lower than the "target boost" - up to about 1.8 BAR, if memory serves. I didn't think that was unusual until I got a log from a working example that continued straight up to 2.5 BAR while the "target boost" sat at about 2 BAR.

Worth looking at the boost pressure control actuator in a data log, too. You can then see if this is coming in to limit boost pressure or if it's basically just open loop and not making enough boost (as was the case with P6ULK's example). From memory, the PWM on the boost pressure control sits at about 45% until it starts limiting boost, where it drops, ultimately to about 5% at full boost.

[Marks DTM Calib]

How much boost pressure are you seeing under load?

P6ULK's was vaguely tracking a little lower than the "target boost" - up to about 1.8 BAR, if memory serves. I didn't think that was unusual until I got a log from a working example that continued straight up to 2.5 BAR while the "target boost" sat at about 2 BAR.

Worth looking at the boost pressure control actuator in a data log, too. You can then see if this is coming in to limit boost pressure or if it's basically just open loop and not making enough boost (as was the case with P6ULK's example). From memory, the PWM on the boost pressure control sits at about 45% until it starts limiting boost, where it drops, ultimately to about 5% at full boost.

2.0 Dti has a different turbo I think, its variable vain where as the 2.0 Dti is a standard waste gate setup.

Hence generaly it sits with the boost valve set for 100% until boost pressure is reached before it vents the exhaust gases.

The turbo we removed was in bad shape though, plenty of play in the spindle and the inlet pipes barely swelled when it came on, much much better with the replacement one.

[Marks DTM Calib]

So:
Y22DT - Garrett GT1849V (Vaiable Vane)
Y20DT - Garrett G15 (Waste Gate)

[TheBoy]

Anyone know where sells the little rubber connectors used for the vac pipes. And vac pipes come to that (vac pump to turbo solenoid is a tad short, and has signed of rubbing (but not bad enough to cause a fault), so may as well change it)?

Euroshiteparts, GSF, Hellfrauds and a local factors all let me down.

[TheBoy]

Should add, I did find a split rubber, but that is not the fault. Temporarily replaced with a short bit of leak-off pipe.

The leak-off pipes look like they have seen better days, but do not appear to be leaking. Is that the issue with leak-off pipes (ie, they leak)?

[TheBoy]

How much boost pressure are you seeing under load?

P6ULK's was vaguely tracking a little lower than the "target boost" - up to about 1.8 BAR, if memory serves. I didn't think that was unusual until I got a log from a working example that continued straight up to 2.5 BAR while the "target boost" sat at about 2 BAR.

Worth looking at the boost pressure control actuator in a data log, too. You can then see if this is coming in to limit boost pressure or if it's basically just open loop and not making enough boost (as was the case with P6ULK's example). From memory, the PWM on the boost pressure control sits at about 45% until it starts limiting boost, where it drops, ultimately to about 5% at full boost.

From memory, it boosts up to 2.2 on the old turbo (or up to about 2.6 with the vac pump directly connected to the wastegate ). Would need to recheck with the replacement turbo.

Any value in taking a snapshot on a 0-60 dash?

[Marks DTM Calib]

Anyone know where sells the little rubber connectors used for the vac pipes. And vac pipes come to that (vac pump to turbo solenoid is a tad short, and has signed of rubbing (but not bad enough to cause a fault), so may as well change it)?

Euroshiteparts, GSF, Hellfrauds and a local factors all let me down.

Basicaly the same as used on most of the V6 setup so second hand items should be easily sourced.

As for leak off pipes, the generaly draw air in and if very bad show slight signs of fuel

[P6UL K]

Anyone know where sells the little rubber connectors used for the vac pipes. And vac pipes come to that (vac pump to turbo solenoid is a tad short, and has signed of rubbing (but not bad enough to cause a fault), so may as well change it)?

Euroshiteparts, GSF, Hellfrauds and a local factors all let me down.

Halfords sell a small tray containing varied Y, T & straight connectors for vacuum piping, as for the piping you can buy it by the meter on eBay... I use Mr Silicone

[anddyy88]

Anyone know where sells the little rubber connectors used for the vac pipes. And vac pipes come to that (vac pump to turbo solenoid is a tad short, and has signed of rubbing (but not bad enough to cause a fault), so may as well change it)?

Euroshiteparts, GSF, Hellfrauds and a local factors all let me down.

gm want £6 each for these little rubber connectors , on my vectra with the same engine i just changed all the vaccum hoses for some silicone hoses off ebay (3mm i think) and just pushed them striaght on, no need for the connectors with the silicon hoses.

when was the last time the inlet manifold/swirl flaps cleaned out, i found it made a huge difference to mine when it was cleaned , messy job but well worth it to get the power back and helped reduce turbo lag a bit.

[TheBoy]

when was the last time the inlet manifold/swirl flaps cleaned out, i found it made a huge difference to mine when it was cleaned , messy job but well worth it to get the power back and helped reduce turbo lag a bit.

Probably never. TIS implies that the pump has to be bled with KM948 once the injection pipes have been off, which means its not something I can currently do.

[TheBoy]

With the swirl flaps activated, the engine won't rev beyond about 2k, it just misses as if its running on 3, and belches smoke. Not sure why this would be, as the inlet air should be fast enough by that rpm for the extra inlet valve to work 

[Kevin Wood]

From memory, it boosts up to 2.2 on the old turbo (or up to about 2.6 with the vac pump directly connected to the wastegate ). Would need to recheck with the replacement turbo.

Any value in taking a snapshot on a 0-60 dash?

Next time you've got an evening spare.

Sounds like the boost is present and correct-ish, then. You at least have enough for that not to be the performance issue. Fuel volume / timing might be the culprit?

Not really had much time debugging tractors, so just speculating, really.