Golf 4 GTI-R wont rev past 5500 RPM

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Golf 4 GTI-R wont rev past 5500 RPM

Post by fadeel » Mon Jan 27, 2014 7:46 pm

Hi All,

I have pulling my hair out for this problem, besides all the money I had to spend with no luck!!

I have a 2004 GTI-R and she has 180K kms on it now already. The car used to run like a demon, but now it will not rev past 5500 rpm.

Whats has happend and what is still happening :

The problem just started out of the blue, one day it was fine the next it wasnt.??

1. Replaced the Divertor Valve. - Showed up on the error codes.
2. Replaced the PCV - Did not show any error but replaced anyways.

NO LUCK - still the same

3. Replaced the MAF sensor - No luck.
4. (The money Spinner) - replaced the entire turbo, plus oil feeder lines :???: - No luck
5. Changed out the crank sensor, from a working GTI-R same model, no luck!!

Now I really need assistance! Please someone help.....

What next? I am at my wits end....

PS....we have checked the boost pipers for leaks ( i guess the best way we could removed and replaced)...

Help please.....

Any suggestions would be appreciated.

Regards
Fadeel - Tired and ready to strike a match!
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by BongzThaMr_K » Mon Jan 27, 2014 8:06 pm

Get a diagnostics check done might be a fault in software or perhaps you'll pick up a problem there , goodluck
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Howie-WP » Mon Jan 27, 2014 8:49 pm

BongzThaMr_K wrote:Get a diagnostics check done might be a fault in software or perhaps you'll pick up a problem there , goodluck
+1

This ....... before spending money by guessing what the problem could be.
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by fadeel » Mon Jan 27, 2014 9:53 pm

Thanks for the responses so far....
Just to make it clear...I did the diagnostics and also had the car checked multiple time...on many occations the car car gave no errors...and as it stands right now...as far as computer id concerned there is no errors.
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by PapaJo » Mon Jan 27, 2014 9:58 pm

Get diagnostic check done and run some logs.

If you can install a temporary boost gauge to check your boost.

Check for leaking boost fittings. Any whistle sounds under boost.

Have you had plugs and fuel filter checked? Is your car pulling strong on lower revs and then just does not want to go further.

Have you checked the loud pedal? DBW pick accelorator input from here and it has a variable resistor switch / slide wire and this might be offset. Should pick this up on diagnostic log. Is idling low or where it should be?
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by fadeel » Mon Jan 27, 2014 10:09 pm

Awesome...thanks....I will check the loud pedal switch..and fitting a temp boost gauge.
Just to answer some of your questions...
We have checked the fuel pump even bypassed the cut out to see if it was the fuel pump. Checked the fuel filters as well. Same problem.
We had replaced the Coil packs some time before the problem started.
We also serviced the car, and replaced the cam belt and tensioners...no difference.

Will try your suggestions and revert back.
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Digit Riaan » Tue Jan 28, 2014 7:12 am

Are you doing all this yourself?
fadeel wrote: 1. Replaced the Divertor Valve. - Showed up on the error codes.
What error code is that?
fadeel wrote: PS....we have checked the boost pipers for leaks ( i guess the best way we could removed and replaced)...
How did you check it?
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by fadeel » Tue Jan 28, 2014 7:28 am

Hi,

1. Replaced the Divertor Valve. - Showed up on the error codes. - This I did myself


What error code is that? - I cant remember, but it said in the report to replace the DV.


PS....we have checked the boost pipers for leaks ( i guess the best way we could removed and replaced)... - This was done via a mechanic, and he said that the boost pipes were removed and checked and then I replaced one with a new one as it had a tear in it.

Any other suggestions?
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Killerwatt » Tue Jan 28, 2014 7:34 am

It was probably the pressure drop between turbo and engine error. It tells you to replace the dv.

You should log the following:
Requested Boost
Actual Boost
N75 duty cycle
Airflow
Specified Load
Actual Load
Throttle body position
Requested Air Fuel Ratio
Actual Air fuel Ratio
Ignition timing angle
Timing delay on all cylinders
And also check fuel trims.

Check if any of the actual parameters do not meet the specified.
Is the car stock? If not then what mods do you have on there?
Also where are you located?

If you are unsure how to interpret the logs then you can email them to me and i will have a look.
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by fadeel » Tue Jan 28, 2014 7:45 am

Hi Killerwatt,

Thanks for the reply, I am in Cape Town.

I will log the car and to get the logs again. The car is standard, the only mod (if you want to call it that) is a flat bmc filter.

I will get the logs asap.
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Digit Riaan » Tue Jan 28, 2014 7:52 am

The only way to check for a boost leak is to pressure test the system to 1bar with compressed air like so:

http://www.audizine.com/forum/showthrea ... eak-Tester

Then, start with WOT logging the following blocks using VAG-Com:
003+115+119
001+031+118
002+020+111
001+002+031

There's no point (except wasting money) in replacing things if you do not know 100% what's wrong, but I'm sure you realise that now.
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by fadeel » Tue Jan 28, 2014 8:40 am

hi porno_ster

Thanks a million, I appreciate all the help. We will assemble a device like that and test again. I just sorcing someone to do the logging as well.

I will revert asap. I also agree that throwing good money after bad is just not on.... :(
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Digit Riaan » Tue Jan 28, 2014 8:47 am

fadeel wrote:hi porno_ster

Thanks a million, I appreciate all the help. We will assemble a device like that and test again. I just sorcing someone to do the logging as well.

I will revert asap. I also agree that throwing good money after bad is just not on.... :(
No problem, as Killerwatt said, we can help with deciphering the logs once you have them.
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by ETunersSA » Tue Jan 28, 2014 9:33 am

Check that your TIP is not squeezing closed at those RPM's.

We have replaced a few stock TIP's on the 1.8T where the car would just not want to rev pass a certain RPM (Usually upper RPM band)

Replacing the TIP solved the issue.

Worth a try
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by VELO-GP » Tue Jan 28, 2014 10:42 am

fadeel wrote:hi porno_ster

Thanks a million, I appreciate all the help. We will assemble a device like that and test again. I just sorcing someone to do the logging as well.

I will revert asap. I also agree that throwing good money after bad is just not on.... :(

test your fuel pressure, and check your throttle body - i (Tiaan) picked up this problem on my car
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Digit Riaan » Tue Jan 28, 2014 10:54 am

VELO-GP wrote:...and check your throttle body - i (Tiaan) picked up this problem on my car
Jip, throttle body alignment is a must.

http://www.youtube.com/watch?v=2zrmhDw_v7Y
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Solo786 » Tue Jan 28, 2014 12:06 pm

I would also check the TIP is not collapsing under load.
If thats fine then check the FPR and perhaps the TB.
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by fadeel » Tue Feb 04, 2014 5:18 pm

Hi All,

I have pulling my hair out for this problem, besides all the money I had to spend with no luck!!

Just an update, and once again thanks for all the feedback.

So after all the advise and too and fro, here is what was done and the car is still the same.

1. Did a diagnostic check and it came up with a few error.
2. Replaced the Divertor Valve. - Showed up on the error codes.
2. Replaced the PCV - Did not show any error but replaced anyways.
3. Replaced the turbo with the oem replacement part, as the boost pipes were soft during boost, and it was found that the turbo was cracked between the exhaust housing and the actuator.
4. Replaced the oil feed lines to the turbo.
5. Changed the MAF sensor
6. Checked the fuel filter and fuel pump, as well as the the fuel pressure.
7. Checked for Boost leaks - with a compressor and gauge.
8. Checked N75 Valve - the actuator is responding, so possibly not a boost problem.
9. Swapped out the crank sensor.
10. Had the car at a VW dealer, and here is the answer "We cannot find the problem"

SO - The car still wont rev past 5500rpm, and it is not like it hitting the limiter, it gets to 5500 rpm, and then everything just shuts off!

Any more suggestions would be appreciated.
All the macks in CPT know this car already!

Regards
Fadeel
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by SemiColon » Tue Feb 04, 2014 5:32 pm

Are you sure its not a tdi?
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Sparkz0629 » Tue Feb 04, 2014 5:53 pm

SemiColon wrote:Are you sure its not a tdi?
LOLLLLL!!!! :lol: :lol: :lol:
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Sparkz0629 » Tue Feb 04, 2014 5:53 pm

Did you try what Shaheen advised?

VVVVV
ETunersSA wrote:Check that your TIP is not squeezing closed at those RPM's.

We have replaced a few stock TIP's on the 1.8T where the car would just not want to rev pass a certain RPM (Usually upper RPM band)

Replacing the TIP solved the issue.

Worth a try
Current: 2012 Reflex Silver 6R Polo GTI
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Ex Rides:
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VWicked wrote: I could do 300km/h if I wanted but I don't trust my brakes stopping from that speed so as soon as i hit exactly 241km/h on my garmin i will tap off, generally it takes me me 6.9 sec to get there so I will just cruise the last 5 sec's to allow the car to cool down..
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by PapaJo » Tue Feb 04, 2014 11:52 pm

Sparkz0629 wrote:Did you try what Shaheen advised?

VVVVV
ETunersSA wrote:Check that your TIP is not squeezing closed at those RPM's.

We have replaced a few stock TIP's on the 1.8T where the car would just not want to rev pass a certain RPM (Usually upper RPM band)

Replacing the TIP solved the issue.

Worth a try
:iagree:

Is it cutting out like a fuel or spark cut off or just hang on to the 5500 rpm's?
Longshot.......is exhaust not blocked?
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Digit Riaan » Wed Feb 05, 2014 7:33 am

fadeel wrote:Hi All,

I have pulling my hair out for this problem, besides all the money I had to spend with no luck!!

Just an update, and once again thanks for all the feedback.

So after all the advise and too and fro, here is what was done and the car is still the same.

1. Did a diagnostic check and it came up with a few error.
2. Replaced the Divertor Valve. - Showed up on the error codes.
2. Replaced the PCV - Did not show any error but replaced anyways.
3. Replaced the turbo with the oem replacement part, as the boost pipes were soft during boost, and it was found that the turbo was cracked between the exhaust housing and the actuator.
4. Replaced the oil feed lines to the turbo.
5. Changed the MAF sensor
6. Checked the fuel filter and fuel pump, as well as the the fuel pressure.
7. Checked for Boost leaks - with a compressor and gauge.
8. Checked N75 Valve - the actuator is responding, so possibly not a boost problem.
9. Swapped out the crank sensor.
10. Had the car at a VW dealer, and here is the answer "We cannot find the problem"

SO - The car still wont rev past 5500rpm, and it is not like it hitting the limiter, it gets to 5500 rpm, and then everything just shuts off!

Any more suggestions would be appreciated.
All the macks in CPT know this car already!

Regards
Fadeel
Diagnostic check does not equal logs. Log it as I recommended and them come back with the info. If you keep on replacing stuff you are just wasting time and money and hoping for the best.
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Killerwatt » Wed Feb 05, 2014 7:41 am

:iagree:

Do the stock k03 tips really get sucked closed though?
I thought this was just the k04 cars...
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Re: Golf 4 GTI-R wont rev past 5500 RPM

Post by Digit Riaan » Wed Feb 05, 2014 7:49 am

Killerwatt wrote::iagree:

Do the stock k03 tips really get sucked closed though?
I thought this was just the k04 cars...
I can't see how this will happen on a stock GTI-R system...It most likely an electrical problem, i.e. ECU power cut, spark cut, etc.
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