Author Topic: PO299 turbo underboost code, Loss of power. Possible cam chain issue.  (Read 1182 times)

Offline mayesj86

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Re: PO299 turbo underboost code, Loss of power. Possible cam chain issue.
« Reply #15 on: March 09, 2018, 10:30:56 AM »
Thanks mate.   We do what we can to improve things  :smiley:   I just need to get the MK6 intake bits from the dealer and see if it all marries up because it's the early EA888 engine, so there may be some subtle differences.  VW must have moved the MAF away for a reason  :smiley:

Sounds like your engine is in fine fettle.  14-15bar is factory fresh compression I believe, so yours is certainly up there.  Busted pistons and clogged injectors would show up in the plug colours and/or be oil fouled, so I'm sure it's all good.

Is your power delivery a bit wobbly from time to time, and inconsistent?  Great for a few days, and then back to being sluggish with a strange 'wavy' delivery riddled with flat spots?  Is your turbo noisier than usual these days?  I remember when I picked up the ED30 with 70 something K miles on it, I couldn't hear the turbo at all, but it's very audible now.

I've been taking the turbo intake pipes off a lot recently, testing intakes, and it's always drenched in oil down there having wiped it all off previously.  Literally in a day, it would be soaked in the stuff again.  That much oil accumulating so quickly, plus the reduction in performance has to be the turbo.  Occam and his Razor  :happy2:   I think the bearings are worn out, making it slower to spool up.  The power is there if I keep my foot down, but just feels sluggish getting up there.

Sounds like we have the same driving style.  My PS4s are down to the wear limit markers, so the grip and tramlining are amusing to say the least!

The TTE running around 350hp, but with a big fat midrange and more top end torque would be great, but it would need yet another remap!   I've got a growing list of other jobs that need doing, one of which is the steering rack (and tyres!), so I might just stick a Turbo Technics recon on for now.

I wonder if Turbo Technics will do a discount for 2?  :grin:


Its a shame that the aftermarket units claim to be a bolt on job and away you go but clearly their R&D is that will do and not done very well. Had a wee look at the MK6 stuff and they have moved the MAF a good bit away from the turbo inlet. Seems a far better idea and design. VW don't muck about with R&D and must have a very good reason for it. Keep up the good work buddy with it all very impressed with your outside the box thinking  :congrats:

I call the car a diva buddy  :signLOL:. Some days runs and boost beautifully and others feels sluggish with hellish flatspots.
Initially thought it was boost leaks so checked all connections, changed DV and the usual suspects. Think everything is starting to point to a worn turbo and for the price of the rebuild which does include the 360 deg bearings thought it was well worth trying. The turbo is certainly loader now than when I got her at 78K and the oil consumption is getting slowly worse.

Once the turbo is up to pressure its not to bad but building boost certainly is taking longer. Initially though it was me getting used to the power and car but my mate was in it a few weeks ago and hadn't been since I got it and he mentioned it wasn't as quick as it used to be going by the bum dyno.

I like to drive quickly when the time is right and on the right roads but now have mechanical sympathy and see no need in red lining the car when these things have great mid range and sweet handling. Far more fun IMO carry the corner speed and using the mid range to keep her going.

PS4's are great until about 2/3 worn then they make things a little interesting. Currently have the cross climates on ( always run winter tyres from Oct/Nov time to Mar/April joys of growing up in Shetland) and bloody hell do the grip on these cold wet roads. More road noise but what confidence they give you in cornering and especially braking area.

For the price of the rebuild Vs cost of having to map the car again you'd proably be better off keeping the KO4. The no flat spot would definatly be the thing to swing the descision.....or sell the TTE and have the cash for all other issues and have a new KO4 plus extra for other toys  :laugh:

Could ask if they would do a discount on more than one would be a good business idea for them if that's their price and the service they look like they will deliver. Could see more KO4'd cars using them if they would maybe do a forum discount.

Offline Pudding

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Re: PO299 turbo underboost code, Loss of power. Possible cam chain issue.
« Reply #16 on: March 09, 2018, 11:49:53 AM »
I guess that's the difference between real engineers and sales/marketing engineers  :wink:

I bought a complete MK6 intake pipe assembly from ebay last night, turbo to MAF, for the princely sum of £28.  On first glance, the only thing missing is the DV return spout for our KO4 engines.  I'm sure I can fudge something together for that, or tucked down out of sight in the turbo pipe is an inlet for the MK6's PCV, so I could use that for the DV return instead  :happy2:

Sounds like our cars are exhibiting exactly the same symptoms and I definitely think it's turbo wear.   Eventually the shaft will get so loose, things will start rubbing and making horrific screeching noises.  Hopefully we'll get it sorted before then.   I think very frequent changes of Mobil 1 is the only thing keeping mine clinging on for dear life  :grin:

Yep, my car literally feels awful to drive at the minute.  Very vague, crashy and sloppy feeling.  I think it's a combination of the knackered tyres and the rack dying!

I called TT today and they have no remanufactured KO4s in stock, only brand new units at £735+VAT, which is £300 cheaper than VW! 

Lead time for reman' on receiving our old turbos is 5-7 days.  That isn't feasible for me as it's my work transport, so I think in my situation, it's better to fit the TTE420 over a weekend and just run it at wastegate spring pressure until I get it mapped  :smiley:    I believe I can hop up to Revo Stage 3, so wouldn't need to pay for a full map.

Even at wastegate spring pressure (8 or 11 psi, you get a choice of springs in the box), just having a brand new nice sealed turbo on there will improve consistency.  Not bothered about smashing dyno records  :smiley:



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Offline mayesj86

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Re: PO299 turbo underboost code, Loss of power. Possible cam chain issue.
« Reply #17 on: March 09, 2018, 12:30:18 PM »
I guess that's the difference between real engineers and sales/marketing engineers  :wink:

I bought a complete MK6 intake pipe assembly from ebay last night, turbo to MAF, for the princely sum of £28.  On first glance, the only thing missing is the DV return spout for our KO4 engines.  I'm sure I can fudge something together for that, or tucked down out of sight in the turbo pipe is an inlet for the MK6's PCV, so I could use that for the DV return instead  :happy2:

Sounds like our cars are exhibiting exactly the same symptoms and I definitely think it's turbo wear.   Eventually the shaft will get so loose, things will start rubbing and making horrific screeching noises.  Hopefully we'll get it sorted before then.   I think very frequent changes of Mobil 1 is the only thing keeping mine clinging on for dear life  :grin:

Yep, my car literally feels awful to drive at the minute.  Very vague, crashy and sloppy feeling.  I think it's a combination of the knackered tyres and the rack dying!

I called TT today and they have no remanufactured KO4s in stock, only brand new units at £735+VAT, which is £300 cheaper than VW! 

Lead time for reman' on receiving our old turbos is 5-7 days.  That isn't feasible for me as it's my work transport, so I think in my situation, it's better to fit the TTE420 over a weekend and just run it at wastegate spring pressure until I get it mapped  :smiley:    I believe I can hop up to Revo Stage 3, so wouldn't need to pay for a full map.

Even at wastegate spring pressure (8 or 11 psi, you get a choice of springs in the box), just having a brand new nice sealed turbo on there will improve consistency.  Not bothered about smashing dyno records  :smiley:


Its a shame when you put your faith in a companies that is supposed to make products to as good or better spec than OEM for performance enhancements and in the end causes more issues and potential damage to the car. These intakes aren't cheap either which for me makes it a whole lot worse.

That's a great find and price buddy keep us posted on your findings and how you got on with the modifications. Not entirely sure I will be going the intake route but if it works great and corrects all the annoying issues would consider it myself. Tucking the DV return away would be a nice wee touch to keep it nice and clean looking in the engine bay. Out of interest if you don't mind me asking would you be using the MK6 intake pipe married up to the rest of the VWR intake from the MK5 with your flexi addition?

I'm just waiting for the screetching noises to start but like yourself it gets oil changed every 5k with Castrol edge ( no particular reason for that oil just always used it and the better halves mini uses same spec so bought in bulk last time opie had a sale). My evo 4 turbo decided to start chewing through the housing many years ago and what a racket it makes and did some severe damage as it let go quick throwing turbine bits in places they should never meet  :doh:

Even a off the shelf unit that's a great price....wonder how its so much cheaper then VW and with the 360 deg bearings is a better turbo? Gotta love dealer pricing.

I was quoted the same for lead time. Mine is my daily but thankfully better half works from home so could borrow her car when the time comes. Have booked a wee off work at the end of April so hoping to get it off and back before having to really need it again. Will get suspension and injectors changed at the same time and be good to up the boost then hopefully  :laugh:

Will go well with the TTE fitted would love one myself. Would you be thinking of stage 2 or 2+ power from the TTE with a nice slab of mid range or tone it back a wee touch and enjoy not having the flat spot?  Big power has never been my thing I find it more pup talk I much prefer to have a car that drives the way I want it.

Offline Pudding

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Re: PO299 turbo underboost code, Loss of power. Possible cam chain issue.
« Reply #18 on: March 09, 2018, 05:48:24 PM »
I guess that's the difference between real engineers and sales/marketing engineers  :wink:

I bought a complete MK6 intake pipe assembly from ebay last night, turbo to MAF, for the princely sum of £28.  On first glance, the only thing missing is the DV return spout for our KO4 engines.  I'm sure I can fudge something together for that, or tucked down out of sight in the turbo pipe is an inlet for the MK6's PCV, so I could use that for the DV return instead  :happy2:

Sounds like our cars are exhibiting exactly the same symptoms and I definitely think it's turbo wear.   Eventually the shaft will get so loose, things will start rubbing and making horrific screeching noises.  Hopefully we'll get it sorted before then.   I think very frequent changes of Mobil 1 is the only thing keeping mine clinging on for dear life  :grin:

Yep, my car literally feels awful to drive at the minute.  Very vague, crashy and sloppy feeling.  I think it's a combination of the knackered tyres and the rack dying!

I called TT today and they have no remanufactured KO4s in stock, only brand new units at £735+VAT, which is £300 cheaper than VW! 

Lead time for reman' on receiving our old turbos is 5-7 days.  That isn't feasible for me as it's my work transport, so I think in my situation, it's better to fit the TTE420 over a weekend and just run it at wastegate spring pressure until I get it mapped  :smiley:    I believe I can hop up to Revo Stage 3, so wouldn't need to pay for a full map.

Even at wastegate spring pressure (8 or 11 psi, you get a choice of springs in the box), just having a brand new nice sealed turbo on there will improve consistency.  Not bothered about smashing dyno records  :smiley:


Its a shame when you put your faith in a companies that is supposed to make products to as good or better spec than OEM for performance enhancements and in the end causes more issues and potential damage to the car. These intakes aren't cheap either which for me makes it a whole lot worse.

That's a great find and price buddy keep us posted on your findings and how you got on with the modifications. Not entirely sure I will be going the intake route but if it works great and corrects all the annoying issues would consider it myself. Tucking the DV return away would be a nice wee touch to keep it nice and clean looking in the engine bay. Out of interest if you don't mind me asking would you be using the MK6 intake pipe married up to the rest of the VWR intake from the MK5 with your flexi addition?

I'm just waiting for the screetching noises to start but like yourself it gets oil changed every 5k with Castrol edge ( no particular reason for that oil just always used it and the better halves mini uses same spec so bought in bulk last time opie had a sale). My evo 4 turbo decided to start chewing through the housing many years ago and what a racket it makes and did some severe damage as it let go quick throwing turbine bits in places they should never meet  :doh:

Even a off the shelf unit that's a great price....wonder how its so much cheaper then VW and with the 360 deg bearings is a better turbo? Gotta love dealer pricing.

I was quoted the same for lead time. Mine is my daily but thankfully better half works from home so could borrow her car when the time comes. Have booked a wee off work at the end of April so hoping to get it off and back before having to really need it again. Will get suspension and injectors changed at the same time and be good to up the boost then hopefully  :laugh:

Will go well with the TTE fitted would love one myself. Would you be thinking of stage 2 or 2+ power from the TTE with a nice slab of mid range or tone it back a wee touch and enjoy not having the flat spot?  Big power has never been my thing I find it more pup talk I much prefer to have a car that drives the way I want it.

Yeah it's always the same - the benefits are oversold and exaggerated, and the downsides left to the customer to discover and figure out!

That is indeed the plan initially.  If that doesn't work out, I have 2 other plans.  1) use a MK6 airbox - it should drop straight in, and 2) relocate the battery to the boot using Audi TT-S cables and parts, and then use the much bigger TT-S airbox  :happy2:  All in the name of science and experimentation  :smiley:

I don't think physical contact is far off!  I think it's a right of passage as a turbo car owner to have at least one turbo blow on you  :grin:   I've had about 3 let go on me over the years, and an engine  :doh:  I shudder to think of the £1000s spent (or wasted?  :grin:) on cars over the years.

I believe the brand new unit is bought direct from BorgWarner, so won't have any VW markings on it, but then again I don't think the OEM one has any anyway, just a riveted-on plate.  The Turbo Engineers (TTE) buy them in directly from BW as well, as do VW, so I reckon they're around the £550 mark trade.  VW just lump on a 50% markup!  I'm not sure if the new unit would have 360 bearings in it, we'd have to ask them.

Are you doing yours yourself?  If you are, all of the turbo gaskets, seals, studs, nuts, everything you need is all cheap.  Around £35 for all of it  :happy2:  Turbo Technics recommend replacing the oil drain hose, but I might just clean it instead as it's a braided metal job and pretty pricey I think.

To be honest, I just want it to feel like it did when I bought it with Revo 1 on it.  Just breathing on the gas pedal lit up the wheels.  It was so punchy and smooth.  It's become progressively more and more sluggish to the point of being quite horrible to drive.  I hope the TTE injects the fizz back into it again! 

I did some data logging the other day and measured a peak MAF reading of 214 g/s.  That's about 270hp. So my 2+ is making 30hp less than stage 1  :grin:
The target and requested boost matched though, which is slightly worrying.  Could mean a busted piston.  I'll have to do another compression test at the weekend if it ever stops raining!  If all is well and it is just the turbo, then yeah, I'll be aiming for around the 350 mark.  If I had forged pistons and rods in it, I'd go for the full 400+ beans!













Black Edition 30 with manually selected cogs, a beefier clutch, some extra boost and them Whiteline thingies, otherwise standard.

Offline paulmcgrath

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Re: PO299 turbo underboost code, Loss of power. Possible cam chain issue.
« Reply #19 on: March 12, 2018, 10:09:08 PM »
@mayesj86
@Pudding

So after a few days thinking and some mathematics, I've come to the decision that it would be a bit of a stretch committing to upgrading the turbo and everything that comes with it by upgrading everything more or less all at once.

I cant readily visit turbo technics or any of the other aforementioned turbo specialists as I live in Dublin, Ireland but I was given a price of 400 euro for a reconditioned turbo (270-degree bearing) plus 350 euro fitting.

I've enquired with all the "turbo specialists" in my vicinity and they all dismissed the 360-degree bearing request as "never heard of it" with one even suggesting its "forum make believe chatter" which isn't worth doing. In the next breath, the same gentleman cautioned that if I was to remap my car then he wouldn't be able to honor the 12-month warranty on the 270-degree bearing unit.

So seeing as I do have plans to remap it would you guys advise me to buy the reconditioned turbo off of the suggested sellers from England and to also request the 360 bearing be installed in this reconditioned unit?
I think pudding advised to expect to pay a ball-park figure of 500 gbp to the suggested turbo specialists in England...
is this price including the 360 bearing in the reconditioned turbo and if not how much more should I expect to pay for this mod?
I'll be calling them up tomorrow anyway so I'll soon find out and report back.

Secondly I'm looking at either the pipeworxx downpipe for 280GBP or a second hand, 2-year-old BCS powervalve downpipe for 120 and the final option is a new Uk made T304 stainless steel 3" ebay downpipe for 117gbp.
Which of the three would you recommend?

Lastly I know the turbo removal and refitting needs the engine to be dropped at one side so is it best if I get the downpipe and have it fitted with the turbo at the same time? or is Downpipe fitting way less invasive and could I delay the buying and fitting of a downpipe to a later date without taking too much of a hit in the pocket by paying the labour for that down the line?

Cheers lads

Offline Pudding

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Re: PO299 turbo underboost code, Loss of power. Possible cam chain issue.
« Reply #20 on: March 13, 2018, 09:25:02 AM »
I would see if you can find a tired turbo locally for little money and ship it off to Turbo Technics in England.   I would give a turbo supplier who doesn't know what a 360 bearing is a wide berth!  Turbo Technics rebuild cost of £390+VAT includes the 360 degree bearing.

The turbo comes out from above, or by dropping a driveshaft and out from below according to my research online.  I have also seen one guide suggest removing the dogbone and tilting the engine forwards 20mm with a strap tied to the subframe.   And I've seen another guide where there is no mention at all of moving the engine!

It does look like an involved job for sure, but on a warm day with a few beers, taking your time, it should be fairly straightforward.   Workshops quote around 5 hours to swap it out, so that's a good chunk saved doing it yourself, and a lot of knowledge gained also  :happy2:

https://www.pelicanparts.com/techarticles/Volkswagen_Golf_GTI_Mk_V/63-ENGINE-Replacing_Your_Turbo/63-ENGINE-Replacing_Your_Turbo.htm

http://www.eurojetracing.com/sites/default/files/pdfs/install-docs/k04%20install%20final.pdf
Black Edition 30 with manually selected cogs, a beefier clutch, some extra boost and them Whiteline thingies, otherwise standard.