Mazda 6 Forums UK

Technical Section => Engine/Transmission/Powertrain/Exhaust => Topic started by: Darren1717 on June 15, 2018, 07:23:18 pm

Title: Turbo stopped working?
Post by: Darren1717 on June 15, 2018, 07:23:18 pm
Hi all,

New to this forum, and hoping you guys can help me!

Firstly, I’m in Kent, and we have an 09 plate Mazda 6ts2, 2.2td. I’ve actually had it since new, it was my company car for 4 years and we then bought it for my wife as a runaround when I renewed. I clocked up about 118k miles on it in that time, and it was always serviced at the main dealers when on lease. Since we bought it, she has only done another 10k on it in 5 years! When she does use it now, maybe three or four times a month, it has a run of 25 miles on A roads and motorways.

Ok, so I used it the other week and it seemed to have lost its zoom zoom. I immediately noticed the apparent lack of turbo kicking in, and then the engine management light came on. No strange noises or smoke, so I don’t think it’s broken. I bought an obd reader and looked at the codes;

One for dpf... though it has had the dpf light flashing for a while (not static), and I’m told this is just to indicate it wants a service and for you to take it to a rip off merchant, sorry... dealership, to have it checked, so I’m ignoring that for now.
It had a couple of error codes around the mass air flow sensor, and looking on google, this can cause no end of issues, so I have replaced that, along with a new air filter. Still no turbo. I also put some of that EGR cleaner up the air intake whilst running the engine, just for good measure... seems to be the done thing on google also?!?
So the next codes I’m looking at are to do with the wastegate valve, high and low voltage sensed???
Now, if I’m right in what I have read, it would seem that the wastegate valve being faulty can cause the turbo to not work, and that’s seems to be the symptom, so I’m thinking that’s the next thing to check, either faulty valve or wiring?

My questions are;
Do you think this may well be the culprit? How would you go about it?
Where the hell is the wastegate valve?  :-\ (I can’t even see the turbo in the bay!)
How hard is it to get out? (I don’t mind tinkering with spanner’s etc., but mechanic I am not. I’d handle maybe changing an alternator, (and I can see that!), changing the brakes, but dropping the gearbox kind of work is not me, if you get my drift.
Can it be checked?
Can it be replaced?
Does anyone have any other suggestions?!?

I’d hate to lose the car... it’s been great, but I’m not going to spend thousands on it, now that it’s almost 10 years old and with that mileage on it.

Appreciate any help from those ‘in the know’!

Cheers
Darren
Title: Re: Turbo stopped working?
Post by: apav on June 16, 2018, 10:44:56 am
Change the oil and reset the ECU while you are pushing the car for power.

Did that MAF error code go away?

Somebody else had posted a similar ECU flashing and boost problem. It may be mechanical and change part of the turbo or it can be from the ECU and you need to change the boost controllers.

It may be cheaper to go for a free turbo diagnosis from a specialist.
Title: Re: Turbo stopped working?
Post by: Darren1717 on June 16, 2018, 11:27:54 am
Hi Apav

Yes, the MAF errors have now gone.
I may have misunderstood you, but I’m not pushing for more power, I’m trying to get the factory fitted turbo to work again.

Resetting the ecu is done by removing the battery, right? I haven’t done that since fitting the MAF, so maybe I should try?

Thanks
Title: Re: Turbo stopped working?
Post by: aeroadster on June 16, 2018, 01:39:25 pm
Have you checked it's not a clogged EGR?  I take it that there's still no noise from the turbo.

http://www.mazda6forums.co.uk/workshop/manuals/workshop/mazda_6_2010_5_my_workshop_repair_manual546.pdf (http://www.mazda6forums.co.uk/workshop/manuals/workshop/mazda_6_2010_5_my_workshop_repair_manual546.pdf)

If this link doesn't work you can access the Workshop manual from this site and find it.
Title: Re: Turbo stopped working?
Post by: Darren1717 on June 16, 2018, 05:19:29 pm
Have you checked it's not a clogged EGR?  I take it that there's still no noise from the turbo.

http://www.mazda6forums.co.uk/workshop/manuals/workshop/mazda_6_2010_5_my_workshop_repair_manual546.pdf (http://www.mazda6forums.co.uk/workshop/manuals/workshop/mazda_6_2010_5_my_workshop_repair_manual546.pdf)

If this link doesn't work you can access the Workshop manual from this site and find it.

Thanks for the info and link... still no strange noises and drives fine, just not as quick!

Edit... ok, just saw the ‘workshop manuals’ link on the homepage. Duh! :-[
guess I just remove the EGR and clean it out? Will have a try.
How can I access the workshop manual?
Title: Re: Turbo stopped working?
Post by: aeroadster on June 16, 2018, 08:42:40 pm
You need to you Microsoft Internet Explorer from your PC or laptop - not Chrome.

There are other copies of this online, but the dynamic links don't work
Title: Re: Turbo stopped working?
Post by: apav on June 17, 2018, 08:51:21 am
Still, replace the oil because you are not driving it at low revs.

This is how you reset it:

https://www.youtube.com/watch?v=NV3_TYoWzAs
Title: Re: Turbo stopped working?
Post by: Darren1717 on June 17, 2018, 02:51:40 pm
You need to you Microsoft Internet Explorer from your PC or laptop - not Chrome.

There are other copies of this online, but the dynamic links don't work

Ah... that’s why I only get the front page on my iPad!
Thanks
Title: Re: Turbo stopped working?
Post by: Darren1717 on June 17, 2018, 02:53:00 pm
Still, replace the oil because you are not driving it at low revs.

This is how you reset it:

https://www.youtube.com/watch?v=NV3_TYoWzAs

Thanks for the link... I’ll do that this pm.

Any idea how to check the EGR for clogging? Presumably just unbolt it and have a good clean up?

Any ideas on the wastegate valve errors?

Thanks in advance
Title: Re: Turbo stopped working?
Post by: Darren1717 on June 17, 2018, 05:58:43 pm
Hi
Thanks for the help so far...
I have reset the flashing dpf service light, disconnected the battery and removed most of the air intake then used some egr cleaner. Put it all back together, cleared the dtc codes and took it for a spin up the motorway for half an hour, then read the codes...

Results;
Car drives fine, no weird engine noise, no smoke, no dash warning lights at all.
Still feels like someone flipped an ‘off’ switch on the turbo. There is no boost feeling when the revs climb.
Codes upon return were;
P011600
P009600
P011100
P018100
P139100
P200200

I have no idea where to look next... help,please!  :-\
Title: Re: Turbo stopped working?
Post by: apav on June 18, 2018, 07:40:04 am
Googling the codes, you start with coolant temperature, pass on intake air sensors and completes with DPF efficiency.

Somebody else was posting the same problems, called the dealer and said something about the sensors.

If you could locate the sensors, you could clean them up. The sensors will cost to replace them so maybe some confirmation from an expert before trying by luck, could save you money.
Title: Re: Turbo stopped working?
Post by: aeroadster on June 19, 2018, 01:43:05 pm
Sorry, I've not had a look at all your codes to interpret them yet.

Did you unbolt and clean that EGR thoroughly?  Sometimes, you'll also see a huge amount of carbon build up on the inlet manifold.  Clean what you can there too with a carb cleaner and a toothbrush.

Now you have the repair manual, locate and clean both your MAP and MAF sensors.   It would be interesting to see whether dirty sensors are creating a downstream problem with restriction in power.  They do on so many other cars.

Title: Re: Turbo stopped working?
Post by: Darren1717 on June 23, 2018, 08:36:03 am
Googling the codes, you start with coolant temperature, pass on intake air sensors and completes with DPF efficiency.

Somebody else was posting the same problems, called the dealer and said something about the sensors.

If you could locate the sensors, you could clean them up. The sensors will cost to replace them so maybe some confirmation from an expert before trying by luck, could save you money.


Thanks apav
Title: Re: Turbo stopped working?
Post by: Darren1717 on June 23, 2018, 08:39:20 am
Sorry, I've not had a look at all your codes to interpret them yet.

Did you unbolt and clean that EGR thoroughly?  Sometimes, you'll also see a huge amount of carbon build up on the inlet manifold.  Clean what you can there too with a carb cleaner and a toothbrush.

Now you have the repair manual, locate and clean both your MAP and MAF sensors.   It would be interesting to see whether dirty sensors are creating a downstream problem with restriction in power.  They do on so many other cars.

Thanks...

I haven’t managed to get the manual yet, as I’m on an iPad and need IE! I’ll have to do it at work, to get to the EGR etc!
For the above reason, I’ve not yet got it off to clean, but sounds like the next job. I have put a new MAF sensor on... will find and clean MAP sensor.

Cheers

Title: Re: Turbo stopped working?
Post by: apav on June 24, 2018, 06:34:03 am
Somehow when you try to use the forum with the IE, the section with the service manual disappears and you cannot access it. Even when you try to copy paste the link from Firefox, it does not do anything.
Title: Re: Turbo stopped working?
Post by: Darren1717 on June 24, 2018, 06:08:52 pm
Somehow when you try to use the forum with the IE, the section with the service manual disappears and you cannot access it. Even when you try to copy paste the link from Firefox, it does not do anything.

Does anyone have the pdf downloaded, that can be emailed?  ;)
Title: Re: Turbo stopped working?
Post by: aeroadster on June 25, 2018, 10:06:31 pm
Sorry, I've not had a look at all your codes to interpret them yet.

Did you unbolt and clean that EGR thoroughly?  Sometimes, you'll also see a huge amount of carbon build up on the inlet manifold.  Clean what you can there too with a carb cleaner and a toothbrush.

Now you have the repair manual, locate and clean both your MAP and MAF sensors.   It would be interesting to see whether dirty sensors are creating a downstream problem with restriction in power.  They do on so many other cars.




Thanks...

I haven’t managed to get the manual yet, as I’m on an iPad and need IE! I’ll have to do it at work, to get to the EGR etc!
For the above reason, I’ve not yet got it off to clean, but sounds like the next job. I have put a new MAF sensor on... will find and clean MAP sensor.

Cheers

Darren,

Try these links, to give you access to the PDF versions for the GH model?  The embedded dynamic links within the document may not work so you'll have to scroll through the document each time which can be tedious.

https://www.mazdabg.com/ftp-uploads/Mazda/6/ (https://www.mazdabg.com/ftp-uploads/Mazda/6/)
https://www.mazdabg.com/ftp-uploads/Mazda/6/Mazda6%20(GH).pdf (https://www.mazdabg.com/ftp-uploads/Mazda/6/Mazda6%20(GH).pdf)
Title: Re: Turbo stopped working?
Post by: Darren1717 on July 15, 2018, 09:27:56 am
Update...

Ok, so I have the egr off, eventually. Have cleaned it up overnight in a soak.
Anyone know how I can test it whilst off the car?
Resistance settings or something??

Ta
Title: Re: Turbo stopped working?
Post by: apav on July 16, 2018, 05:35:26 am
Did you find the manual or any other instructions, or was it more about playing with it until you made it?

I think you have to put it back and if the car works better, then the cleaning did the trick.
Title: Re: Turbo stopped working?
Post by: Darren1717 on July 21, 2018, 11:04:23 am
No, had no luck at all with a manual... it’s the GH Diesel engine and the manuals seem rarer than rocking horse manure!
Bit of trial and error getting it off but managed it.
Now just need to try it out, but I’m not hopeful that it has cured the problem
 :'(
Title: Re: Turbo stopped working?
Post by: apav on July 22, 2018, 08:29:41 am
I see. Did you take any photos?

The EGR will not last for ever but a good clean can give it extra life. Did you clean up the inlet manifold as well?

Did you check the pipes for cracks and splits? These will reduce your power and the turbo will not spool.

It is a bit tight where the turbo is, but somehow people on top the pipes, they manage to release the actuator and make sure it is free. That would then pin down the problems to electronics.
Title: Re: Turbo stopped working?
Post by: Darren1717 on August 07, 2018, 04:41:03 pm
Ok... so just by way of an update for you...

Took the car to a local Indy Mazda guy. He hooked it up and found a timing chain stretch of 10.9, which I’m told is bad! Car had the recall carried out years ago, but hey.
I agreed to a £900 new chain... the next day he called and said that after checking, the turbo has gone also! So, not worth repairing anything.

Sadly, she is now off to the great scrapyard in the sky.

Thanks for your help guys.

 :'(
Title: Re: Turbo stopped working?
Post by: apav on August 08, 2018, 09:52:15 am
Unfortunately this is the story with these cars. They get big bills that never stop. The only way to make them work for you is to use them for long period/mileage. Then the cost per day/mile comes down to normal maintenance. The problem is that these cars seem to age very quickly around the decade combined with high mileage. So the rust will kill the rest.

If you had the car the car for 100K miles and you had to pay this £2K bill now, then it would be 2p/mile and you would hope that it would run for another 100K miles and so that would bring the cost down to 1p/mile. Probably you will have to decide based on the 2p/mile and this seems to be a reasonable cost to accept on top of the normal maintenance as it is unlikely that the chain will do another 100K miles.

Scrapping the car is a way out but if you could sell each wheel for the £50 minimum they go on eBay, plus that much for the odd panel, you will make much more than the £99 scrap value. Maybe you could sell the car as salvage with a faulty engine and somebody will do a DIY replacement engine for less than the £2K repairs and then keep it or sell it for a small profit. In the age of finance, I am not sure if anyone repairs cars anymore.
Title: Re: Turbo stopped working?
Post by: Darren1717 on August 08, 2018, 04:35:23 pm
I actually sold it today to copart... got £300, which saves me the hassle of stripping it down.

Did manage to retrieve the brand new Denso MAF sensor that I put on it, all of 2 miles ago in my original fault finding quest... so that might recover some of the original £90 cost, on eBay or similar!
Title: Re: Turbo stopped working?
Post by: apav on August 09, 2018, 10:23:52 am
Sad story and I wonder whether we will get something like £300 if we get into an accident. For sure you would not sell the car for £300 if it was working but then if you are in a accident, there is a very good chance that the insurance will only pay that much and then you will have to figure out what bicycle to buy to replace the 6.

If your sensor is bought new from a shop, maybe you could return it and get a refund. If you bought online, maybe you will have to pay the postage, but still it should be a straight forward refund. You just say that you tried it and there is no difference, so you would like to return it. In the past I had received an oil filter for the old car from Car Parts 4 Less which of course came in a Euro Car Parts box. It was one of these filters that do not have the metallic cover, it is just the paper filter that you fit in a plastic attached to the engine. Somebody had opened it and tried to do something with it. This did not stop them sending it to me. I contacted them and I got a replacement but you may have a chance to return it to the shop like that guy returned the oil filter. It is still crazy that a sensor goes for £90 and the whole car for £300.