Amarok Limp Mode

[Cohan]

Good evening everyone.

I have a 2012 Amarok 2.0 TDI auto. The vehicle has a massive repair history. It loses power when on full throttle and mostly happens in 4th to 5th gear.

I have replaced the bi-turbo, replaced cylinder head, tandem pump, ecu, cluster, ignition, throtlle valve, egr, wiring loom, boost pressure sensors, map sensors, tried another exhaust, injectors, rail, intake manifold, tappet cover, cooler, vacuum lines, accelerator pedal, have had the EGR deleted from the file. I also checked reference voltage between the consumers, even ran new wires to actuator to bypass common consumer on the same line.

I have honestly tried everything I could think of.
If anyone has any idea of what I could try next, your help would really be much appreciated.

TIA

Regards,
Kokkie

[stephenplumb]

Do you have VCDS or access to someone with it? That seems like a good place to start.

[Oppies3800]

Replace the vehicle

[Cohan]

Do you have VCDS or access to someone with it? That seems like a good place to start.

I do have VCDS and ODIS, we have logged the vehicle and compared it to another vehicle, and everything seems to be the same on both vehicles.

[Cohan]

Replace the vehicle

We have tried that aswell hahaha. They paid us to take it back.

[jonoB]

Did you buy the vehicle brand new? What is the mileage?
Do you know the service history ?

[Stephan van Tonder]

Have you logged fuel pressure - actual to requested?.
Boost - actual to requested.
N75 actuation percentage?.
tested for a boost leak on the intercooler and plumbing?.

[Cohan]

Have you logged fuel pressure - actual to requested?.
Boost - actual to requested.
N75 actuation percentage?.
tested for a boost leak on the intercooler and plumbing?.

Yes have just done the fuel pressure, all in spec.
Boost is requesting 2.9 and actual 2.4 ( this is after the vehicle has been mapped and actuator adjusted ). We have then put the map back to stock, and set the actuators back, and boost in spec. Pressure tested the entire system. Then only tested the cooler side, and then only the engine side. All in order N75 has been replaced. The only thing I can think of is that there might be a hairline crack in one or several cylinders, causing the vehicle to loose pressure and last resort change the box and see. We have litterally changed and checked all sensors and component except for the block and box.

Thanks for the reply, its greatly appreciated

[Cohan]

Did you buy the vehicle brand new? What is the mileage?
Do you know the service history ?

Hi Jono,

To be honest its not my vehicle, im just the technician working on the vehicle. I work for VW and we have done whatever factory has asked us. There is no history from a dealer point of view, I dont know what has been done prior to vehicle. Mileage curently is at 124 041km and its a 2013 model.

[AfricaOffroad]

I can but only recommend a box of matches ...

[Pietsweis]

Full throttle in 4th / 5th gear is when fuel demand is at it's highest.

I had similar symptoms (Mostly at high speed and hard acceleration) on the Hilux which frustrated the hell out of me and one day noticed that the spring clamp on the fuel filter intake was not in position.

The assumption is still that a bit of air got sucked into the system in high demand conditions because as soon as the clamp was correctly placed the problem disappeared and have not returned almost 2 years later.

Is there any possibility that the fuel system can get air in under high fuel demand? Hose with a hairline crack or a connection not 100% secure?

[Cohan]

Full throttle in 4th / 5th gear is when fuel demand is at it's highest.

I had similar symptoms (Mostly at high speed and hard acceleration) on the Hilux which frustrated the hell out of me and one day noticed that the spring clamp on the fuel filter intake was not in position.

The assumption is still that a bit of air got sucked into the system in high demand conditions because as soon as the clamp was correctly placed the problem disappeared and have not returned almost 2 years later.

Is there any possibility that the fuel system can get air in under high fuel demand? Hose with a hairline crack or a connection not 100% secure?

Hi Piet,

I have done a fuel pressure test and inspected all the hoses and lines. Im getting 4.7 bar before the filter and 4.5 at the high pressure pump and cannot see any leaks.

Thanks for the reply