Ibiza 130 and limp mode

[Quickshift]

Ok guys I realy need your help on this one. I have just finished building a mk3 Golf which I fitted with a 03 Ibiza PD130 engine and 6 speed box.I used the full Seat loom,ecu,clocks etc.

The car starts and drives fine until between 60 & 70mph it goes into
limp mode.If I turn off the key and restart the car it is fine until I reach
60ish again.

There is also loads of black smoke(I mean loads) out the back when I
drive it on,it is even very smokey at 60mph in 6th gear.

I had it plugged into vag-com and there was no faults,we even drove
it plugged in and nothing came up when it went into limp mode.

I took off the turbo,stripped and cleaned it,cleaned the erg and intake
manifold but its still the same.

The engine(ASZ) has only 1735 miles on it,I fittedd a front mount intercooler,
K&N cone filter and took off the cat.

Please help.

 

[Viking]

Sounds like you have a boost leak somewhere. A turbo pipe split or not fitted correctly. Cheapest place to start.

 

[Nathanio]

Yup boost leak somewhere. Check the boost pipe is tightly on the n75 (my last tolly spat the boost pipe off and did exactly as you described)

 

[Quickshift]

All the pipes are on good and tight. How much of a leak would be needed
to cause this?

Would it be something as small as a pin hole in a weld on my stainless pipes
or would it need to be a big split/pipe off.

Tanx for the help guys,keep it coming.

 

[Viking]

Depends how much boost you have before it goes into limp mode. Kinda hard to tell from text.

Have you driven a pd130 when it's sorted? And if so how does yours compare?

Black smoke from the exhaust is either too much fuel or not enough air. We'll take it that the fuelling is correct, as there's not much can go wrong there if you've got everything from the same donor car. So that leaves not enough air. Check your air filter isn't clogged, then you've got plenty of air supply to the turbo. Then check all the hoses from turbo to intercooler and back up to the intake, that will verify that there's plenty of air coming from the turbo to the intake.

Then check the vacuum supply pipes are all connected to the correct components, bit of a nightmare if you don't know where they go. If the ecu is trying to adjust the turbo vnt mechanism and the vacuum pipe is wronglyconnected, then you'll have problems aplenty.

Anticipating your next question "How can I tell", here's a diagram to help. It's from a VW ALH engine, but the details should be fairly similar.

 

[muddyboots]

The Ibiza 130 doesn't use all the separate vac control valves as shown in the diagram, there's one combined box (on the Ibiza, fitted above the o/s strut top) from which runs 3 or 4 vac hoses.

Seems strange there are no fault codes registered if it's gone into limp mode.

To get LOADS of black smoke would need a fairly big leak, like a hose half popped off.

 

[muddyboots]

When you say you reach 60mph, does the problem always occur bang on the same speed ?

In other words, if you gently increase speed with light throttle does it still go limp at 60, or only when you're nailing it ?

 

[sssstew]

if youve got vag com then log boost and go for a drive to see what its doing.

 

[Viking]

The Ibiza 130 doesn't use all the separate vac control valves as shown in the diagram, there's one combined box (on the Ibiza, fitted above the o/s strut top) from which runs 3 or 4 vac hoses.

Thanks for putting me right on that. Can't be chewed taking the pic down, so use it for reference purposes, but don't take too much notice of all the d etails, eh.

 

[Quickshift]

Thanks lads.I took the air filter off altogether and went for a spin but
still the same. All the pipes are tight and in good condition.

If I nail it,it will limp near enough bang on 60 but if I drive easy its
more near 70.

@ Viking, thanks for that diagram but as muddyboots said the Ibiza is
different. Anyone have a diagram for the single black box set up so I
can check my pipes are in the correct order?

 

[Quickshift]

Just a quick update lads.I changed the MAF this evening and the smoke is
all gone but I still have a limp @ 60.

Is there any chance the control valve box could be fooked.

It might be no harm to mention this build is going on for 3 years
so god knows what might have stuck/siezed over that time.

 

[MATT RILEY]

I take it you used the lift pump out of the fuel tank?
Have you tryed disconecting the maf plug so the ECU goes to a set map?

 

[Quickshift]

I used a pump from a mk3 VR6 and also fitted the diesel cooler
on the return line.

I did disconnect the maf plug but it had no power at all,like limp
mode or even a bit worse.

 

[MATT RILEY]

Hmm have you taken the ABS and the hydro/elc steering into consideration,these all send signals to the engine ECU?Not the easyest transplant in the world.Maybe a leon 130 engine ECU is needed?

 

[MATT RILEY]

Where have you fitted the boost presure sensor? after the intercooler?

 

[Quickshift]

There is no ABS,traction control or airbags and these 3 faults are showen
on the ecu but my Seat garage (also a vw nut) told me they will not
affect the running of the car.

Yes,its fitted between the intercooler and the inlet manifold.Is that a
boost pressure sensor or a air temperature sensor?

what exactly is its job?

 

[muddyboots]

Yes,its fitted between the intercooler and the inlet manifold.Is that a
boost pressure sensor or a air temperature sensor?

IIRC, the two are combined.

The first things I would do are:

1) Make sure you've got all the vac hoses connected to the vac controller in the right order (if I still had my Ibiza I'd have a look!)

2) Start logging boost pressure, MAF output, inlet air temps, fuel temps with vag-com to see if they all look sensible. If you're not sure what is "sensible" then post your logs on here, we should be able to help.


What's odd is that limp mode isn't occurring at an exact speed, which suggests it's somehow engine related. But if you're nailing it, you've already been through the full rev range in 1st & 2nd, which to do successfully suggests all the vac controls are working, so why does it wait until the higher gears before going into limp
Sounds daft, but there couldn't be something under the bonnet moving due to the airflow when the car gets up to speed ? And perhaps blocking an intake or disturbing some wiring.

 

[gazjones]

- Depression connection
q Between the tandem pump and the brake servo
q With return valve
2 - Exh. gas recirculation valve
q Checking → Chapter, Exh. gas recirculation valve: checking
3 - Pressure capsule
q For intake manifold flap
4 - Air cleaner
5 - Vacuum reservoir
6 - Pressure capsule
q For regulating supercharging pressure
q Part of the turbocompressor
7 - Solenoid box
8 - Solenoid box connector
thats hoiw the pipes should be connected, hope this helps

 

[maxcars1]

Cheers for that Gaz - that should help Quickshift check his connections. If you need another Vacuum Solinoid I have a spare

 

[Quickshift]

Tanx a million gaz,im gonna check them right now.

@maxcars1,I might take you up on that offer,It has to drive to Inters
in two weeks.