w203 om642 limp mode after few seconds, changed actuator but no luck.

[ChrissM]

Hi guys. Driving 2005 w203 c320 (om642), lots of miles, over 185k. So the issue is standard limp mode and the car won't go over 3k rpm. I did a quick diagnostics with my phone, and it showed P0244 (Turbocharger (TC) wastegate regulating valve A - range/performance problem) + in combination with P2510 (Engine control (EC) relay, sense circuit - range/performance problem). Went for the STAR diagnostics for more detailed information got 2510-001 Check component Y77/1 (Boost pressure regulator).

Seemed like my actuator was working, when I turn on the ignition it goes up/down, when I start the car it also is working for the first seconds when I press gas pedal. Also for those few seconds, I can rev the engine all the way. But after like 5-10 seconds it goes to that limp mode and the actuator gets stuck and is not moving.

All right, I got a refurbished turbo actuator anyway, bet the problem is the same. I can rev the engine after few seconds on startup, I also tried to start the engine and immediately drive it with full throttle. I can drive it for longer and it has power, but it jerks on acceleration. Then when I stop and idle, it turns on the limp mode.

I also found this topic https://mhhauto.com/Thread-Really-stuck-need-help-W211-E320-CDI-fault-2510-001 , but he did not solve the issue. Sounds really bad and I am already getting depressed I have cleaned EGR valve, back pressure sensor. Should I try resistor mod on swirl flap motor? I will visit indie mechanic with STAR diagnostics, maybe there are some key things to look for?

 

[bembo449]

where did you get the refurbed actuator and yes , do the resistor mod asap , such a cheap and easy thing to do that will save a lot of potential hassle

 

[ChrissM]

where did you get the refurbed actuator and yes , do the resistor mod asap , such a cheap and easy thing to do that will save a lot of potential hassle

The refurbished actuator came from the local turbo workshop. It is the same G-277 as previous one. Any downsides or long-term side effects of the resistor mod?

 

[bembo449]

be more specific please ? no non at all pal , I have a 300c CRD with the same engine , and as soon as I got it I did the resistor mod , no issues at all and ive cured several MB with problems related to swirl motor failure by carrying out this mod

 

[Doug1234]

Disconnect the actuator and check the movement of the vane operating arm on the turbo.
Leave the actuator disconnected from the arm, get some wire and tie the arm in the up position (vanes fully open ) and start and let the engine idle ... if the fault is with the actuator it should still occur but I would expect the vanes are sticking and hence the range performance problem.
Below from another thread my actuator /vanes issue
Clear the codes
Disconnect actuator from turbo linkage
Use a piece of wire through the turbo linkage and tie it off on something nearby so it holds the linkage in the full ‘up’ postion
Drive it and see how it behaves ,along with any codes that pop up.


Here is why....My Jeep with om642
Big flat spot between 3.5-4k revs when pulling hard in 3-4 gear change.
This would put up p0046 / actuator code
Keep away from those revs and all ok.
Pushed it hard one day and couple of large hiccups and constant p0046 (actuator) p0403 (egr) and quite a few drivetrain 4wd diff actuators.
Clear these all off and p0046 eventually became stored and would not clear..egr code would often pop up along with some hissing under bonnet.
Clear egr code and drives ok but only to 2k revs and turbo will chatter and stall above that.
When this first occurred I checked turbo linkage movement... it went up and down ok but the last 1/4 movement at the bottom of travel had no feel.
After about a month of driving along slowly ( too busy at work to get time to replace turbo yet) I disconnected actuator and found linkage on turbo not moving at all /solid.. so vanes in turbo are seized.
With actuator disconnected the stored p0046 has cleared
P0403 egr code pops up if I let turbo chatter by going over 2k revs and the gentle hissing under bonnet comes back and does so if in traffic fir more than ten minutes
Drives slightly better before its half warm for some reason, I have to encourage it to change gear sometimes by tapping shifter lever over.

Code reader I use is icarsoft bcii jeep dodge chrysler etc.... I can have the p0403 egr code on the Jeep reading side but interestingly if I use the generic obd side it only registers as p0404 ?.

Mercedes car may give more codes than the Jeep , for instance the Jeep om642 software will not flag up injector misfire etc.
I have only ever had the main engine management light come on twice , the flashing lightning bolt is the main one .
The swirl motor although working was deleted with the resistor mod long ago.
I have never seen either high or low over boost codes.
So just p0046 actuator...p0403 egr ... and then just lots of 4wd differential and transfer case actuator codes and these are just coming along for the ride due to the above codes as its the Quadra drive 2 all singing and dancing AWD system .
I will be changing egr cooler seals along with turbo once I get the time to get at it.
I believe mine is jammed due to exhaust manifold flexi breaking up

 

[ChrissM]

Disconnect the actuator and check the movement of the vane operating arm on the turbo.
Leave the actuator disconnected from the arm, get some wire and tie the arm in the up position (vanes fully open ) and start and let the engine idle ... if the fault is with the actuator it should still occur but I would expect the vanes are sticking and hence the range performance problem.
Below from another thread my actuator /vanes issue
Clear the codes
Disconnect actuator from turbo linkage
Use a piece of wire through the turbo linkage and tie it off on something nearby so it holds the linkage in the full ‘up’ postion
Drive it and see how it behaves ,along with any codes that pop up.


Here is why....My Jeep with om642
Big flat spot between 3.5-4k revs when pulling hard in 3-4 gear change.
This would put up p0046 / actuator code
Keep away from those revs and all ok.
Pushed it hard one day and couple of large hiccups and constant p0046 (actuator) p0403 (egr) and quite a few drivetrain 4wd diff actuators.
Clear these all off and p0046 eventually became stored and would not clear..egr code would often pop up along with some hissing under bonnet.
Clear egr code and drives ok but only to 2k revs and turbo will chatter and stall above that.
When this first occurred I checked turbo linkage movement... it went up and down ok but the last 1/4 movement at the bottom of travel had no feel.
After about a month of driving along slowly ( too busy at work to get time to replace turbo yet) I disconnected actuator and found linkage on turbo not moving at all /solid.. so vanes in turbo are seized.
With actuator disconnected the stored p0046 has cleared
P0403 egr code pops up if I let turbo chatter by going over 2k revs and the gentle hissing under bonnet comes back and does so if in traffic fir more than ten minutes
Drives slightly better before its half warm for some reason, I have to encourage it to change gear sometimes by tapping shifter lever over.

Code reader I use is icarsoft bcii jeep dodge chrysler etc.... I can have the p0403 egr code on the Jeep reading side but interestingly if I use the generic obd side it only registers as p0404 ?.

Mercedes car may give more codes than the Jeep , for instance the Jeep om642 software will not flag up injector misfire etc.
I have only ever had the main engine management light come on twice , the flashing lightning bolt is the main one .
The swirl motor although working was deleted with the resistor mod long ago.
I have never seen either high or low over boost codes.
So just p0046 actuator...p0403 egr ... and then just lots of 4wd differential and transfer case actuator codes and these are just coming along for the ride due to the above codes as its the Quadra drive 2 all singing and dancing AWD system .
I will be changing egr cooler seals along with turbo once I get the time to get at it.
I believe mine is jammed due to exhaust manifold flexi breaking up

Turbo arm moves freely, and turbine is in fairly good condition. So I am sure that it is not a turbo issue. I got additional question if I change the turbo actuator, do I need to calibrate it together with turbine ? Considering it is the same, based on numbers.