Turbo Stuck High, Open, Low

[Radiofence]

If the damage is where the loose intake pipe plugs in...mines broken too. Big chunk missing. I guess where someone has forced the pipe in and flexed something

[Nondisclosed]

If the damage is where the loose intake pipe plugs in...mines broken too. Big chunk missing. I guess where someone has forced the pipe in and flexed something

Exactly there yes, thought the same thing to be fair with the amount it must of been taken out for repairs.

[Radiofence]

Some cheap air filters if old can start to tear at the end folds then let air get past, so might be worth getting a nice new filter too.

[Nondisclosed]

Progress report

- cleaned intercooler
- replaced damaged hose from intercooler to engine
- inspected hose from air box to turbo ( no visible damage)

Took it out for a spin, might just been in my head hit seemed to have more pull in the lower gears. Got to about 55mph and the dreaded chimes of death and lights came up. Plugged it in, and turbo sensor A saying stuck open again.
Restarted the van, came up almost straight away, drove a short distance and it's not come back up but I know it will as soon as I drive more than 100 metres Where do I start now? Still revs but lots of loss of power

20250607_102452.jpg

[knobby1]

Progress report

- cleaned intercooler
- replaced damaged hose from intercooler to engine
- inspected hose from air box to turbo ( no visible damage)

Took it out for a spin, might just been in my head hit seemed to have more pull in the lower gears. Got to about 55mph and the dreaded chimes of death and lights came up. Plugged it in, and turbo sensor A saying stuck open again.
Restarted the van, came up almost straight away, drove a short distance and it's not come back up but I know it will as soon as I drive more than 100 metres Where do I start now? Still revs but lots of loss of power

20250607_102452.jpg

Have you actually replaced the turbo vane actuator..?? I read your comments but no mention of it being replaced.

Lord Knobrot

[Radiofence]

You can open it pretty easily and examine the cogs inside

[Radiofence]

Look for damage like thus...

[Nondisclosed]

Progress report

- cleaned intercooler
- replaced damaged hose from intercooler to engine
- inspected hose from air box to turbo ( no visible damage)

Took it out for a spin, might just been in my head hit seemed to have more pull in the lower gears. Got to about 55mph and the dreaded chimes of death and lights came up. Plugged it in, and turbo sensor A saying stuck open again.
Restarted the van, came up almost straight away, drove a short distance and it's not come back up but I know it will as soon as I drive more than 100 metres Where do I start now? Still revs but lots of loss of power

20250607_102452.jpg

Have you actually replaced the turbo vane actuator..?? I read your comments but no mention of it being replaced.

Lord Knobrot

I'm going to say it was replaced when the turbo was 18 months ago, is this what I should be looking at now? I'll have to take it off today

[Nondisclosed]

20250608_095256.jpg

Dropped the horse shoe clip aswell

Tested the motor, works. Did notice that one of the contact pins wasn't perfectly aligned so I'm going to try and straighten it up. Can't see how that could of happened in a closed unit though, or whether it was or not marrying up inside.

[Nondisclosed]

What are the chances that this unit is dud? Just trying to gather as much info before I order another. If for example this unit isn't the fault, Where's the next step? When I say I tested the motor, it was direct to the motor contacts.

[knobby1]

What are the chances that this unit is dud? Just trying to gather as much info before I order another. If for example this unit isn't the fault, Where's the next step? When I say I tested the motor, it was direct to the motor contacts.

If the actuator motor and little plastic gears are working ok, maybe the vanes in the turbo itself a sticking, not unheard of.

Lord Knobrot

[metalworker0]

should it have some grease on the gears ?

all the best.mark

[Radiofence]

That doesn't look like a genuine hella inside. Wot markings are on it.

[Nondisclosed]

What are the chances that this unit is dud? Just trying to gather as much info before I order another. If for example this unit isn't the fault, Where's the next step? When I say I tested the motor, it was direct to the motor contacts.

If the actuator motor and little plastic gears are working ok, maybe the vanes in the turbo itself a sticking, not unheard of.

Lord Knobrot

When I disconnected the arm from the actuator, I manually moved the arm, I wouldn't say it was rough, but ever so slightly it had a little bit of resistance, but really not much. Quickly moved smoothly

[Nondisclosed]

That doesn't look like a genuine hella inside. Wot markings are on it.

When I opened it and cross referenced it to your picture, I saw straight away that it was very cheap looking. The QR code takes me to the turbo number. It has G59 on the side. But from what I can see there is no 6N number.