Fault code 00544 overboost protection?

[Jonas_R]

Just had a cutoff, this is what i could get out of the ECU:

00544 - Maximum Boost Pressure Exceeded
06-10 - Signal to High - Intermittent

So what to do?
All new samco kit fitted, all small hoses and wg hose are new
N75, MAF, ISV, BOV (from audi s3), MFTS, lamdba all brand new.
Mark H o-ring mod is also fitted.

So i going to change WG membrane and fit oil catch tank.

Where can i get a pressure tester and can i somehow test the WG membrane?

Any other ideas are welcome.

00513 - Engine Speed Sensor (G28)
03-00 - No Signal


Guess this bad boy is just because the engine is turn off right?

/Jonas R.

[Uukrul]

Just had a cutoff, this is what i could get out of the ECU:

00544 - Maximum Boost Pressure Exceeded
06-10 - Signal to High - Intermittent

So what to do?
All new samco kit fitted, all small hoses and wg hose are new
N75, MAF, ISV, BOV (from audi s3), MFTS, lamdba all brand new.
Mark H o-ring mod is also fitted.

So i going to change WG membrane and fit oil catch tank.

Where can i get a pressure tester and can i somehow test the WG membrane?

Any other ideas are welcome.

00513 - Engine Speed Sensor (G28)
03-00 - No Signal


Guess this bad boy is just because the engine is turn off right?

/Jonas R.

The first thing in my checklist is wastegate hose, two pieces - one from turbo to WG frequency valve, and the second from WGFV to WG - maybe it was not properly tightened ? Is the WGFV (N75?) working ? (do ECU output tests if possible).

After that do WG membrane check. You can connect hose to upper chamber and try to pressure/vacuum test it. If it is leaking - try changing WG membrane.

The third thing - faulty MAP sensor (inside the ECU)... but it is unlikely.

...and yes, G28 is because engine is not running.

[Jonas_R]

The first thing in my checklist is wastegate hose, two pieces - one from turbo to WG frequency valve, and the second from WGFV to WG - maybe it was not properly tightened ? Is the WGFV (N75?) working ? (do ECU output tests if possible).

After that do WG membrane check. You can connect hose to upper chamber and try to pressure/vacuum test it. If it is leaking - try changing WG membrane.

The third thing - faulty MAP sensor (inside the ECU)... but it is unlikely.

...and yes, G28 is because engine is not running.

Well Hoses should be tighten oki, and N75 valve is brand new and working i presume since it gets the correct boost values. I will re check those hoses, is it possible to apply pressure at the hose that goes from the WG to n75? I mean unplug the hose from the WG and the apply pressure to see if it is leaking somewhere in those hoses?

How do i do ECU output test? Something i can do from VAGCOM?

Where on the wg should i apply pressure?
I already have a new WG membrane so iam going to change that soon.

/Jonas R.

[Uukrul]

Well Hoses should be tighten oki, and N75 valve is brand new and working i presume since it gets the correct boost values. I will re check those hoses, is it possible to apply pressure at the hose that goes from the WG to n75? I mean unplug the hose from the WG and the apply pressure to see if it is leaking somewhere in those hoses?

I guess no, it is not possible, unless you plug all the holes in the turbo/engine air intake system.

How do i do ECU output test? Something i can do from VAGCOM?

Yes. VAGCOM has output tests - http://www.ross-tech.com/vag-com/tour/out_test.html

Where on the wg should i apply pressure?
I already have a new WG membrane so iam going to change that soon.

You can apply pressure to the lower chamber - that is where WG hose from N75 is connected, or to upper chamber.

Applying positive pressure to lower chamber should open WG (0.4 bar I believe). Negative pressure (vacuum) to upper chamber should open WG too.

[S2central.net]

JOnas - you are going to need some pressure testing equipment for this test, and a set of bungs to blank of plumbing at certain places to isolate the system.

I know you fitted new Samco hoses, but have you checked/changed/upgraded the intercooler o-ring ?

Simple tests with a MityVac (hand vacuum pump) on the upper chamber of WG should be done to verify the diaphragm isn't leaking.

Using a garage airline connected to the boost signal hose (where it normally connects to compressor housing) can check for leaks in the hose that leads to the WG lower chamber via the WGFV. WIth the the ignition off, your WGFV should steer all pressure in that direction.... If you blank the hose where it connects to WG, then it *should* be airtight in the control hoses.

Be patient - these leaks can be hard to find, but you need to invest in some equipment and get access to a safe air line that provides a controlled flow of compressed air.


Paul

[Jonas_R]

JOnas - you are going to need some pressure testing equipment for this test, and a set of bungs to blank of plumbing at certain places to isolate the system.

I know you fitted new Samco hoses, but have you checked/changed/upgraded the intercooler o-ring ?

Hi Paul,
I fitted a mark h mod instead, so it should be oki there.

Simple tests with a MityVac (hand vacuum pump) on the upper chamber of WG should be done to verify the diaphragm isn't leaking.

Using a garage airline connected to the boost signal hose (where it normally connects to compressor housing) can check for leaks in the hose that leads to the WG lower chamber via the WGFV. WIth the the ignition off, your WGFV should steer all pressure in that direction.... If you blank the hose where it connects to WG, then it *should* be airtight in the control hoses.

when you say upper chamber, you where the arrow points? Is it to much with 1.5 bar pressure?

Be patient - these leaks can be hard to find, but you need to invest in some equipment and get access to a safe air line that provides a controlled flow of compressed air.


Paul

I got a air compressor at my garage so that will be no problem. is there any way that i can test the small hoses?
I was thinking about unplugging the hose at the BOV and apply pressure there and the block of the 3 hoses that goes into the intake manifold. This would mean that there would be pressure on the pressure gauge, map sensor, fuel regulator and perhaps something else. Is this possible?

/Jonas R.

[valjo]

mybe it sounds funny but i have the similar problems, and i found out that my spark plugs were bad, and i replaced it, and car goes good now