Hello:)

I want to introduce myself first a little bit before going further to my big big problem which I currently have.

First Sorry for my bad english but I am trying to find any solution for my problem since I am totally lost and asked in several forums but I couldnt get THE final answer nor was at my Ford Dealership which also couldnt find the solution.

My Car is a 2010 Ford Fiesta 1.6 TDCi 90HP with now 300.000km. First of all why I just dont sell it and buy something different? Well, it was my first brand new car and therefore a lot of memories and my plan is to keep this car forever.

So basically the car got a complete makeover in terms of dampers, springs, axle bushings, wheel bearings etc.. the complete suspension/chassis side. In addition I renewed a lot of Engine/Gearbox Parts. I want to list them up, that you have a better overview:


- All Tubes ( Coolant Tubes, Intercooler Tube, Tube from Air Filter To Turbo etc..)
- Boost Pressure Control Valve
- Intake Bridge
- Valvecover
- Intake Manifold Module
- Intake Pipe Sensor
- Intercooler
- Engine Water Cooler
- Climate Condensator
- Fuel Filter
- Cylinder Head Cover with Sealing
- AirFilter
- OilPan with OilFilter
- All Engine/Gearbox Bushings/Bearings
- Engine Oil
- Coolant Fluid
- New Clutch with all parts and fluid
- Gearbox Sealings
- The thing which is controlling the mechanically wastegate of turbocharger
- EGR Vent / Exhaust Gas Recirculation Valve

So basically a lot of things and the car was running for almost 10.000km fine. And then the problem occured.

Basically if you start the engine and go for a drive (it takes 2-3minutes normal driving and you push the accelerator pedal very much but in a high gear for example), then suddenly you can feel the turbo switching off and the car goes into emergency mode. So less power. There is very often NO error message in the dash but you can cleary feel the car is in emergency mode and only revs to 4000rpm maximum or 3500rpm. I cannot remember precise. Now... Once you switch the engine off and wait for a minute and you start again... you have the complete power again until 1-2minutes and the car goes again into emergency mode.  You can repeat it as many times but the last times it stayed in emergency mode and also noted down/showed an error. Only one. It was P0299 Underboost.

Now.. I am basically complete broken down because I dont know what to do anymore because I was at my Dealership and they said... just buy a new turbo. Honestly... I did now and my last two options would be the NEW Turboloader and a complete cleaned DPF (diesel particulate filter) because the car's coolers are running on high mode everytime, also when I only drove 8 minutes normal and park the car, the coolers in the front are running in high mode for atleast 5minutes. Then it's quiet again.

Can somebody of you help me in any way please? I will now renew the turbo and the dpf but then Idk what to do anymore.

In Addition I attach some pictures here of the turbo, maybe it is the issue.

The oil on that boost pipe looks scary but it's perfectly normal.  There isn't any oil on the exhaust side of the turbo, and I can't see any scoring in that side of the housing which suggests there isn't any play in the turbine shaft bearing.

The intake side picture is interesting though.  It looks like the impellor blades are all 'chewed' at the ends.  Is that just a trick of the light on the picture?  Are you using an aftermarket foam air filter or still a paper original filter?

Really it would be best to check the live data to see what the actual boost pressure is, especially at the point where it drops into limp mode.  Personally I suspect one of your aftermarket boost pipes isn't holding boost perfectly and is blowing open slightly under high pressure.  It may just need the clamp tightening or may be best to replace with an original pipe.  Usually you can see a boost pipe leak by a thin splatter of oil residue that's blown from it.

The fan running all the time is a separate issue.  That may point to a DPF fault.  Though I'd be more inclined towards an electrical fault.  Did Ford find any DPF fault codes?

Hello @TomsFocus

Thanks For Your Reply.

No they are indeed "chewed". I am using an Aftermarket Air Filter from MANN-Filter.

 

I can attach Live Data where the start of the run is working fine and when going further, Limp Mode comes on. Sadly due to the upload limit, I can only share them via wetransfer link.

https://we.tl/t-Ra1okH2ZNk

The Software used to open is ForScan.

Can you please explain more in detail for me when you said the aftermarket boost pipes isnt holding boost perfectly?
For your information: The intercooler is aftermarket, the pipe from airfilter to the turbo is original, the pipe from turbo to intercooler is original, the pipe from intercooler to intake bridge is original, the air intake is original.

I am pretty sure that everything is tightened up but I will make sure to get my way all through it again and check if tight.

 

Because I have already the new turboloader here, I will fit him next week and get a cleaned DPF. My only fear is, that it will continue like that and then I really dont know what to do anymore.

I am questioning myself now because I could ran 10k km's fine and now it was a nightmare.. only 1-2mins until limp mode and then it stayed there.

Edit: There was only the P0299 Error Code shown when reading the car. The only hint from my side was the car as described is always running up the ventilators in the front when you stop the engine running. Like it gets hot or he's trying to do something with the DPF but it's not working.

 

 

Ok, those chewed fins will be interrupting the airflow and reducing the efficiency of the turbo.  So it may just be that it can't make maximum boost any more.  I have only seen that amount of fin damage on cars with cheap foam air filter though.  Usually the paper filter stops the tiny bits of grit that would cause that.  It is very high mileage though of course.

I thought the pipe with the orange inside was aftermarket.  If all the pipes are original then they should fit perfectly.  Though it would still be worth checking the clamp on every one in case they have loosened since fitting.

 

7 hours ago, TomsFocus said:

I thought the pipe with the orange inside was aftermarket.  If all the pipes are original then they should fit perfectly.  Though it would still be worth checking the clamp on every one in case they have loosened since fitting.

Ahh yea you're right! I replaced the pipe from turbo to intercooler with an aftermarket one. I thought why to pay 190€ for the original one then 70€ for the aftermarket.. only a pipe.. . But I certainly learned very quickly why.. .

The aftermarket pipe was like blowing itself up and down when hitting the accelerator pedal. This was a strange feeling after a while because the pipe got softer and softer. First I thought the P0299 is coming from the pipe and thats why I ordered the factory pipe for 190€ from the dealer again. It's behaving totally different and better but didn't solve the P0299 error.

So I try to give here an update when the new turbo and cleaned DPF is again mounted on the car and I do a longer test drive. I am really hoping for that it is finally solved then, otherwise I honestly dont know.

4 minutes ago, vx1100 said:

EDIT: Sorry For Double Post, I edited wrongly.

 The original Pipe which was fitted since car came out of factory was also inside red/orange. The big difference is that the original pipe is much harder and where the aluminium foil is, is also much much harder then the aftermarket one.

So I try to give here an update when the new turbo and cleaned DPF is again mounted on the car and I do a longer test drive. I am really hoping for that it is finally solved then, otherwise I honestly dont know.

 

 

A different approach of mine would be what if the Oil Pump is not working properly anymore and the engine gets too much heat... would it also go in limp mode? But would it cause the P0299 Error or a different one like Engine Water above 120Degrees or something?

If the oil pump stops working you get a specific red oil can shape warning light on the dashboard.  I don't think that is the problem here.

So Update:

I built in a complete brand new Original Turboloader and a professionally cleaned DPF.

Again the same Problem occurs. PO0299 Fail.  Somehow after restarting / rebooting the car today I could drive as long as I was gentle on throttle pedal. And I found something out:

- At some point you can feel there is not the full turbo pressure. When this occurs this helps:
 

- Press Clutch, rev it into the limiter for 2-3 seconds and then release clutch and continue driving

- Turbo Pressure again full max like it should be

... and this procedure you can continue infinite.

I DONT KNOW ANYMORE WHAT TO DO. Anybody has ideas?

That's frustrating.  

I think I'd suggest a smoke-fill test on the boost pipes & intercooler to see if boost genuinely is escaping somewhere.  

Update:

I've chosen my last option:

- ORIGINAL FORD PART Turbo Solenoid Valve (ca.220€)  (In the Screenshot it's an aftermarket one for 40€)
- ORIGINAL FORD PART Boost Pipes Loom (ca 70€) (from Solenoid Valve outgoing to TurboLoader, Airbox and the spot I took in the screenshot) (3x Pipes In Total)

 

I drove now for atleast 1.5hrs with uphill, downhill, full throttle, half throttle, different gears, different rpms and it finally worked for 1.5hrs.

Anyway I am driving this weekend 800km and I will see if it really works now. I cannot say for now if it was the aftermarket turbo solenoid valve or the boost pipes because I changed both at the same time. I had an aftermarket solenoid valve fitted after the engine revision and it lasted for 8000km. It was 40€. Maybe this is why there is a massive price difference to the ORIGINAL Part.

So Update:

My Underboost Problem is SOLVED.

I drove about 800km yesterday and everything worked properly fine.


For some guys which might have the same problem with P0299 Underboost Failure I would conquer this problem in this way of order:

1) Check the AirPipes which I described via the pictures here. In Case just replace them with ORIGINAL FORD Spare Parts. It was about 80€.
2) Check the Turbo Solenoid Valve (I dont know how to check it but I bought the first one from Aftermarket for 30€ and went 8000km okay with it but sometimes with P0299 Error. Now the FORD ORIGINAL Turbo Solenoid Valve for 220€ is working properly fine just right from the beginning which I didnt had with the Aftermarket when I replaced it in the first 100km)
3) Check If Airbox is sitting properly and is not leaking otherwise replace it with the seals!
4) Check If DPF is free otherwise it needs to be cleaned! (300€ Proper Cleaning and it took the company two days for it.. they told me it was so fully packed that they needed two proper days to clean without damaging it. Also now my car is not running the air vents (cooling) on full power when I stop the engine. Now it's completely silent or stops right when I stop the engine. Before they ran on full power after I stopped the car and engine was off for atleast 2-3 minutes.
5) Check If the pipe from turbo to intercooler is sitting right. (I can only say buy the original pipe then if it needs to be replaced because I had my aftermarket one for 50€ and it was working like *****. When you had much turbopressure the pipe was blowing so much and was extending that I thought it will pop. And when Engine was coming down from rpms it was like implosion... the pipe was like imploded. I bought the original Pipe from FORD for 160€ and it works now fine. A side note: With the aftermarket Pipe because it was extending and imploding... the car power (turbo pressure) was quite funny applied. sometimes at 3k rpm sometimes at 2000 rpm...)
6) Last but least check the turbo itself if it's broken.

That helped for me to solve my problem now.