Fault code P0299 Boost - 2019 Crafter

[MB999]

Hi , i have a PO299 underboost issue i cant get to the bottom of.
i have borrowed a copy of VCDS and ran the codes, its has stated as follows :

vw crafter 2.0 - daua 2019 fwd
drives fine98% of the time, but suffers a po299 underboost when crusing at about 65mph.
drive fine under soft driving, drives fine under heavey footed driving, just doesnt like cruising or easing off ?

i have so far,
tested the vacum to n75 - 25mmhg
tested the vaccum line to turbo - it holds at 20mmhg
replaced the N75 valve
inspected all vac hoses, which seem fine.
looked that the waste gate actuator, it seems to move freely on vac but does have just a tiny amount of "play" in the linkage when closed. (suspect)
looked at egr valve, its clear and the valve itself functions on demand
looked at the egr inlet and oulet hoses, i replaced them and the gaskets both ends.
looked at intercooler hoses, all good, clean inside.
done forced regen on dpf, seems fine.

i do have an exhast leak somewhere, i can semll it, and just today i visably saw a faint trace of smoke coming from either the turbo or the exhaust manifold, i just couldnt trace it
it stinks rich at tick over.

Saturday,29,June,2024,11:59:27:29578
VCDS Version: Release 24.5.0 (x64) Running on Windows 11 x64
[URL='http://www.ross-tech.com']www.Ross-Tech.com[/URL]

                Address 01: Engine       Labels: 04L-907-309-V2.CLB
Control Module Part Number: 04L 906 056 NB    HW: 04L 907 445 C
  Component and/or Version: R4 2.0l TDI   H01 6116
           Software Coding: 001940346324050800000000000000000000000000000000
            Work Shop Code: WSC 00069 790 00016
              ASAM Dataset: EV_ECM20TDI03004L906056NB 005005 (VN54)
                       ROD: EV_ECM20TDI03004L906056NB_005.rod
                      VCID: 7AA6987C6C58617A197-802E
4 Faults Found:

23957 - Boost Pressure Regulation
          P0299 00 [00100111] - Control Range Not Reached
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 209628 km
                    Date: 2024.06.28
                    Time: 19:04:13

                    Engine RPM: 2464.50 /min
                    Normed load value: 94.5 %
                    Vehicle speed: 97 km/h
                    Coolant temperature: 89 °C
                    Intake air temperature: 18 °C
                    Ambient air pressure: 1000 mbar
                    Voltage terminal 30: 13.914 V
                    Unlearning counter according OBD: 40
                    Charge air pressure: specified value: 2.195 bar
                    Charge air cooler inlet: pressure sensor 1 bank 1: raw value: 1613 mbar
                    Mass airflow sensor 1 bank 1 airflow: raw value: 793.7 mg/stroke
                    Exhaust recirc.valve 1 bank 1: posit.feedback - Actual value: -20.81 %
                    Throttl.valve adapt. 1 bank 1: posit feedback - Actual value: 46.06 %
                    Turbine actuator 1 bank 1: posit.feedback - Actual value: 98.80 %
                    Mean injection quantity: 26 mg/stroke
                    Air cleaner degree of soiling: 0.00 %
                    Turbocharg.2 compress.outlet: press.sensor 1 bank 1: raw value: 0 mbar
                    Turboc.1 turbin.bypass valve 1 B. 1: pos.feedback - Actual value: 0.00 %

25958 - Boost Pressure Regulation
          P0299 00 [10100111] - Control Range Not Reached
          MIL ON - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 209628 km
                    Date: 2024.06.28
                    Time: 19:04:13

                    Engine RPM: 2463.75 /min
                    Normed load value: 58.4 %
                    Vehicle speed: 97 km/h
                    Coolant temperature: 89 °C
                    Intake air temperature: 18 °C
                    Ambient air pressure: 1000 mbar
                    Voltage terminal 30: 13.914 V
                    Unlearning counter according OBD: 40
                    Charge air pressure: specified value: 2.195 bar
                    Charge air cooler inlet: pressure sensor 1 bank 1: raw value: 1613 mbar
                    Mass airflow sensor 1 bank 1 airflow: raw value: 794.8 mg/stroke
                    Exhaust recirc.valve 1 bank 1: posit.feedback - Actual value: -20.66 %
                    Throttl.valve adapt. 1 bank 1: posit feedback - Actual value: 45.92 %
                    Turbine actuator 1 bank 1: posit.feedback - Actual value: 98.80 %
                    Mean injection quantity: 27 mg/stroke
                    Air cleaner degree of soiling: 0.00 %
                    Turbocharg.2 compress.outlet: press.sensor 1 bank 1: raw value: 0 mbar
                    Turboc.1 turbin.bypass valve 1 B. 1: pos.feedback - Actual value: 0.00 %

15906 - Glow Plug Control Module
          P064C 00 [00100111] - -
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 209632 km
                    Date: 2024.06.29
                    Time: 11:35:06

                    Engine RPM: 854.25 /min
                    Normed load value: 28.2 %
                    Vehicle speed: 0 km/h
                    Coolant temperature: 15 °C
                    Intake air temperature: 19 °C
                    Ambient air pressure: 1000 mbar
                    Voltage terminal 30: 13.867 V
                    Unlearning counter according OBD: 40
                    Pre-glow time: 2.5 s
                    Glow status: Post-heat
                    Outside temperature sensor 1: B1: raw value: 15.5 °C

 

[MB999]

Also,
Because I’ve got such and eye stinging stink at tick over I looked at the dpf soot/ash figures.
I got the following, but I’m not sure what constitutes good or bad.?
Also, I don’t have any dpf related codes coming up? Is this part of my underboost issue due to back pressure ?

It stinks at tick over
It’s drive fine under granny style driving
It’s driving fine under heavy foot driving

What it gets it’s po299 at it if I ease off the throttle or cruise at around 55-65mph… then it faults?
Could
It be back pressure of exhaust gas from a mucky dpf?

 

[MB999]

I’ve just been underneath the van, with bonnet shut and torch on…. I can see exhaust gas leaking from the big clamp that bolts the turbo to the dpf….
Tried to nip it up but it’s tight.

Could this be the cause of my underboost and stink ?

 

[mmi]

Could this be the cause of my underboost and stink ?

Stink - yes.
Underboost - possibly. Well, surely worth tightening the joint up anyways.
Actually, I think the leak is actualy reflected on the value "Particle filter: Soot mass measured" - would have expected the value to be slightly on positive side.

 

[mmi]

Could you please post

(1) - engine's blockmap data - engine not running (ignition on)
(2) - engine's blockmap data - engine ticking over

VCDS > Applications > Controller Channel Map >


Tick/fill boxes as above and hit Go.

VCDS flashes screens for a moment (when finished hit "Done, Go Back") and there should be files blockmap-01-... in folder C:\Ross-Tech\VCDS\Logs\....

 

[DXX]

I can see exhaust gas leaking from the big clamp that bolts the turbo to the dpf….
Tried to nip it up but it’s tight.

There have been cases reported where this clamp and bolts stretch, normally if they have been disturbed during maintenance. Best to renew.

 

[MB999]

Could you please post

(1) - engine's blockmap data - engine not running (ignition on)
(2) - engine's blockmap data - engine ticking over

VCDS > Applications > Controller Channel Map >
View attachment 248481

Tick/fill boxes as above and hit Go.

VCDS flashes screens for a moment (when finished hit "Done, Go Back") and there should be files blockmap-01-... in folder C:\Ross-Tech\VCDS\Logs\....

I will try, I’m a vcds novice and not great with computers either…. I’ll have a go, thanks

 

[MB999]

There have been cases reported where this clamp and bolts stretch, normally if they have been disturbed during maintenance. Best to renew.

Yes, I’ll get a new clamp ordered as it doesn’t seem to want To tighten any more than it is.

Would a leak here give me an underboost issue ?

 

[DXX]

Yes, I’ll get a new clamp ordered as it doesn’t seem to want To tighten any more than it is.

Would a leak here give me an underboost issue ?

No

 

[MB999]

thanks DXX, i didnt think so...... im sure my dpf is blocked but i havent had a single code to suggest it it?

MMI - i think i had an older version of vcds on my lap top, im just sat in the van now downloading the latest version. the old version didnt have "block maps" for me to get.... I've just downloaded the version it shows in your secreen shot. now ill try and work out how to do what your asking !

 

[DXX]

thanks DXX, i didnt think so...... im sure my dpf is blocked but i havent had a single code to suggest it it?

So do you think the waste gate is opening when you drive it hard? Edit; hard to know if the reduced gas flow through the exhaust due to defective DPF would reduce the turbocharger speed enough to reduce boost pressure.
You mentioned elsewhere it’s a new van (to you), I wonder if it’s possible to mask a DPF fault somehow?

 

[MB999]

here are the two block map files:

engine off/ign on
Engine on

these were both read with the fault codes cleared.

i will now take the van for a drive so it records the fault codes, and then i will run these two block maps for you again.

ill upload them shortly, thanks

 

[DXX]

I’m no expert but doesn’t this mean that the life of your DPF is almost up?

IDE06059,Particulate filter: oil ash mass,85.02, g
IDE06060,Particulate filter ash load limit,110.00, g

Combine that with it being a newly purchased van and the clamp leaking as is normal after disassembly and re-use. Do you think its possible that the previous owner has had it apart to investigate / try and back flush?

 

[MB999]

thats very possible.... i dont know what the figures for a goosed dpf are, i assume these readings are bad

I've just drove the van until it faults again, upload here of the blockmap with ign on/engine off

 

[MB999]

here is the block map after fault read with engine on

 

[MB999]

Worth noting, I’ve not had any dpf related codes,
I’ve not had any dpf related lights in the dash.

I did do a forced regen through vcds and the dpf light on the dash did come on and off as you would expect so I know it works !

Strange that my issue could be blocked dpf but the diagnostic has given no indication to that what so ever?

I did get a po401 - insufficient egr flow, and I stripped the egr and cooler
Off to inspect, but was surprised to see it fairly clean inside? Deffo not blocked, solenoid and valve working Fine… that’s code only came up the once and hasn’t since.

It’s the p0299 underboost which come up a lot,

 

[Dav-Tec]

From experience a leak on the EGR pipes of exhaust manifold can trigger the control not reached fault as it's not building enough boost or dropping off to fast. Under hard load the turbo makes more boost than is escaping under light throttle very little boost any way.

I'd start with resolving the exhaust leak and move forward from the.

Ash mass is high so either dpf is becoming clogged or possibly what @mmi says

 

[mmi]

I’m no expert but doesn’t this mean that the life of your DPF is almost up?

IDE06059,Particulate filter: oil ash mass,85.02, g
IDE06060,Particulate filter ash load limit,110.00, g

thats very possible.... i dont know what the figures for a goosed dpf are, i assume these readings are bad

Well, the numbers for a van with mileage of 130.000 miles - just normal. Still estimated 40.000 miles to go
Actually, we can use VCDS to estimate real condition of the DPF - just need to seal up exhaust leaks. Let's do that before shopping for a new one.

---

Anyways, thanks for the blockmaps - very helpful to build a more refined measurement setup - to try to catch the fault.

Perhaps you could make a recording with VCDS of the following data when the underboost condition happens:

IDE00021 Engine RPM​

IDE00075 Vehicle speed​

IDE00085 Normed load value​

IDE00190 Charge air pressure: specified value​

IDE00347 Air mass: actual value:​

IDE07376 Intake manifold pressure: act. value calculated​

IDE07757 Exhaust recirc.valve 1 bank 1: posit.feedback - Actual value​

IDE07784 Turbine actuator 1 bank 1: posit.feedback - Specified value​

IDE07785 Turbine actuator 1 bank 1: posit.feedback - Actual value​

IDE07789 Turbine actuator 1 bank 1: activation​

IDE07790 Bypass valve for turboch 1 turbine inlet: activation​

IDE07793 Turboc.1 turbin.bypass valve 1 B. 1: pos.feedback - Actual value​

​

VCDS > Select > Engine > Adv. Meas. Values​

Either manually tick all the above mentioned or use attached preset-file (open submenu for Load from top-left)

​

​

IMPORTANT! Tick also the following - Group UDS requests by 7, or 8 whichever works.​

​

​

Please do not forget to START the logging.​

Now start the engine -as would like to catch how the turbo "initiates" itself.​

​

Again, the log file will be folder C:\Ross-Tech\VCDS\Logs\....​

Please post the log file.​

---

Attached a measurement preset file - in VCDS format - NOTE! Please remove the .TXT extension as VCDS needs the file with .U01 extention

 

[MB999]

Well, the numbers for a van with mileage of 130.000 miles - just normal. Still estimated 40.000 miles to go
Actually, we can use VCDS to estimate real condition of the DPF - just need to seal up exhaust leaks. Let's do that before shopping for a new one.

---

Anyways, thanks for the blockmaps - very helpful to build a more refined measurement setup - to try to catch the fault.

Perhaps you could make a recording with VCDS of the following data when the underboost condition happens:

IDE00021 Engine RPM​

IDE00075 Vehicle speed​

IDE00085 Normed load value​

IDE00190 Charge air pressure: specified value​

IDE00347 Air mass: actual value:​

IDE07376 Intake manifold pressure: act. value calculated​

IDE07757 Exhaust recirc.valve 1 bank 1: posit.feedback - Actual value​

IDE07784 Turbine actuator 1 bank 1: posit.feedback - Specified value​

IDE07785 Turbine actuator 1 bank 1: posit.feedback - Actual value​

IDE07789 Turbine actuator 1 bank 1: activation​

IDE07790 Bypass valve for turboch 1 turbine inlet: activation​

IDE07793 Turboc.1 turbin.bypass valve 1 B. 1: pos.feedback - Actual value​

​

VCDS > Select > Engine > Adv. Meas. Values​

Either manually tick all the above mentioned or use attached preset-file (open submenu for Load from top-left)

View attachment 248504​

​

IMPORTANT! Tick also the following - Group UDS requests by 7, or 8 whichever works.​

View attachment 248505​

​

Please do not forget to START the logging.​

Now start the engine -as would like to catch how the turbo "initiates" itself.​

​

Again, the log file will be folder C:\Ross-Tech\VCDS\Logs\....​

Please post the log file.​

---

Attached a measurement preset file - in VCDS format - NOTE! Please remove the .TXT extension as VCDS needs the file with .U01 extention

Thanks MMI, I will try and give this a go tomorrw, allthough I may be out of my depth with this level of tech

I will order a new clamp/collar for the turbo to try and get that sealed up.
I will look into getting the dpf cleaned allthough I think it’s a mine field of snake oil salesmen out there. I don’t mind paying if they know what they’re doing but I’m loathed to do it for some one who does little More than squirt a can of something from Halfords and does a forced regen….

 

[MB999]

From experience a leak on the EGR pipes of exhaust manifold can trigger the control not reached fault as it's not building enough boost or dropping off to fast. Under hard load the turbo makes more boost than is escaping under light throttle very little boost any way.

I'd start with resolving the exhaust leak and move forward from the.

Ash mass is high so either dpf is becoming clogged or possibly what @mmi says

I replaced the egr inlet pipe yesterday as I had suspected this, but on removal it was fairy straight, no pitting or splits etc…. I went to Vw and got a new one anyway, along with new gaskets and spline bolts….

I should also have done the egr outlet pipe , as I know one end of it has a rubber seal, so I’ll ensure that right too.