I Need ALH TDI Help with Limp Mode Issue

I need help diagnosing and fixing a LIMP MODE issue I've been having with my 02 TDI GOLF for a while now. It only does this at random times and can simply be reset by re-keying the ignition and drive fine afterwards.
It seems to do this in low rpm / low boost situations. It will do it when switching from 1st to 2nd gear after leaving a traffic light or stop sign. It will sometimes do it when doing a low speed U-Turn. Or it will simply Limp when just cruising down the Hwy. at 65-80 mph in a low boost situation. Simply cruising with minimal throttle input.
I keep getting a P1538 Fuel Cut Off Valve open circuit / ground intermitent code. Does anyone have experience with this.
Listen to all the parts I've replaced so far!!

[@protectandswerve]

Not yet... Was hoping it could be fixed without pulling turbo. Don't see how the codes I'm getting could be related to a dirty turbo..Plus the vains felt like they moved very freely when I installed the new VNT actuator. But after I do new vacum lines and the check valve near the N75, I guess the turbo will be my next area to look.

[@BMACVAGS]

Have you checked the power output from the alternator, these cars are ultra sensitive to voltage fluctuations. Also did you use a genuine coolant sensor??

[@protectandswerve]

I have not done this. I'll have to see if my VW guy can check this for me. Thank you!!

[@protectandswerve]

Also yes, it was a sensor from VW.

[@ManuelRodriguez-dd4jt]

Limp mode and the orange springs light on? May be The gas pedal sensor , the electronics of the fuel pump or (not very common but the ECU )

[@bouncingover]

I have the same problem with my golf mk4 1.9tdi 1998. Limp mode causes bad fuel temperature sensor in the bosch pump...

[@protectandswerve]

I found a company locally that specializes in TDI. I hope to have an appointment for tmrw. to get it diagnosed. I'll report back what they find. I sure hope they can fix it. They sounded confident.

[@protectandswerve]

He dynoed it stock with just the EGR delete it which was done a few years ago and it did 97, 98, & 99 WHP. We will dyno ot soon after the clutch break-In with the new mods. The package should put me in the 150-170 WHP Range!!!! This thing is a blast to drive now!!! Tons of fun. No CEL's and No Limp mode since the mods either :)

[@termantor28]

I am having the same problems, have you come to any solution yet? Thanks

[@averagefamily4272]

Did you change your vacuum lines yet? there is also a small vacuum line going to the ecu. check that. also check your check valve right off the vacuum pump that is a tee make shire thats not plugged also check the check valve going to the n75 valve the white part should be facing the n75. Good luck

[@organicvids]

thats n18 actuator in beginning of vid. check wiring pins in harness under pump, the large harness left of oil filter. do mr muscle turbo clean. check wiring under battery tray inside loom cover for chafing, check alt pulley, check ground to engine, check battery under load and posts. diconnect ecu electrical connector at ecu check pins and female side reinstall with di electric grease. check ALL electrical plugs reinstall with di electric grease. check all wiring under protective plastic coverings for chaffing. for those who have not solved this issue

[@protectandswerve]

Malach211 It was the ECU. Used one out of another car fixed it. This was after all my mods you must have missed in the comments. Did a vnt17, malone stage 4 tune, SB stg. 2 clutch, injectors, and several other things. It now makes 163 WHP!!

[@organicvids]

Interceptor1255 did u have problems with immobilizer or ignition when u swapped ecu?

[@protectandswerve]

Malach211 Not at all. AARodriguez Corp (Andrew) at fixmyvw.com did the swap and found the new ecu. Swapped it and loaded my tune back. No probs since.

[@bogdanvoda5]

I had the same limp issue problem. The day I changed all the vacuum lines/tubes (you have 2 different sizes) problem was fixed. Have your mechanic change all of them, not just one here and there. all or nothing. its worth it... in my opinion

[@protectandswerve]

Thanks..But you must not have read the other comments. Mines been fixed and modified for more power now. My limping was due to something in my ECU. We replaced the ECU with a known good one and it's not done it again.

[@protectandswerve]

Yeah, I've heard that from another person too.. I guess I'll buy 3 more and replace all of them. It has to be something cause I've replaced the harness as well. Thank you!

[@DIYRooster]

I have done everything that you have done, including a new turbo, and I have also purchased the new veg-com. Did you ever find out what the problem was? It may be the same problem I have..

[@protectandswerve]

No fix yet but some interesting info. Most of the Winter with cool / cold temps, I hardly Ever got it to Limp. Now that it's warmed up, it's started limping more often again. The other day it did it several times during one drive. BUT, I found one thing that I'm a complete idiot about. I found that I haven't replaced my air filter in a LONG while. It was bad dirty. I just replaced it. So far NO limp, But only a few miles since then. I'll keep you posted.

[@protectandswerve]

Interceptor1255 I have NO clue why I'd not thought about the air filter until now. I guess it's the same old thing most people do. We always skip past the most simple things. I still need to replace the vacuum lines and possibly clean / replace the turbo if it keeps doing it.

[@protectandswerve]

Next thing on the list to do with it is to install an aftermarket exhaust and do some custom dyno tuning with Malone and AARodriguez and try to squeeze an extra 15-30 hp out of it. It's already so much more fun to drive with these mods and a basic stage 4 Malone tune.

[@jams2907]

Check out the egr valv make shor the vac is sucking then rev your car to see if stop in between if do the your egr valve need replcing soon or the turbo vains

[@RADPro]

Hope your problem was solved. I have a problem with my 02 jetta tdi smoking. watch here and please help. 2002 VW Jetta GLS TDI Smoking Issue Help

[@franklynbulletmiller4459]

good day all i am having a big issue with my golf 4 1.9 tdi. she starts up but does not continue to idle (just does down after the start up) i checked pump and replaced coolent temp sonsor but the glow plug light continues to flash on the dash board. please help

[@protectandswerve]

+franklynbullet miller I'm not a TDI specialist but have a friend that is. He's who fixed mine. Look up www.fixmyvw.com his name is Andrew Rodriguez. AARodriguez.Corp

[@cgica.2667]

Hi. Did you check if the vacuum vnt it I actuating the turbo vnt? It may be the turbo vnt that is blocked and and the ecu is getting an overboost info and then it goes into a limp mode automatically. It did it to my one.

[@protectandswerve]

You must not have seen all my previous post since this vid. lol It was a bad ECU but only found that after I decided to mod it fairly heavily. I now make 163 WHP and it is a BLAST to drive. No limping either :)

[@melissamicu6934]

a6 quattero transmission problems

[@protectandswerve]

It just dynoed163 whp. They could not get a signal for the torque reading but at 163 hp it's probably in the high 200s probably 260 to 280. This thing is fun!

[@ionutdorgo6187]

Check relay 109 for the fuel cut off valve code

[@protectandswerve]

Read all my comments from a few years ago.. Turned out to be a bad ECU...Didn't a bunch of mods and replaced everything..Still did it until we replaced the ECU.

[@protectandswerve]

Not yet... I've been too busy the last month or two to even mess with it..BUT, the last several times I've driven it, it's not limped at all...Very weird how it's such an intermitent thing.

[@terrydtdi]

Have you resolved the problem with your limp mode? I'm having same issues.

[@protectandswerve]

I have not yet. It seemed to stop doing it as much during the colder weather. I believe it's going to be boost related. I need to get off my behind and replace all my vacuum lines and try to see if that takes care of it.

[@protectandswerve]

Well folks. I'd love to tell you we found the exact cause but due to my decision, we'll never really know. (More on that in a sec). But Andrew Rodriguez / AARodriguezCorp.com FixMyVw.com things it was probably the vacum lines and/or dirty turbo vanes. My next comment will tell what we did to fix it.

[@ollierichards8547]

Did replacing the air filter solve your issue? I also have this problem trying to pinpoint it? please let me know!

[@protectandswerve]

No sir it didn't. I thought for a long while it may have because it ran better and didn't limp for over 100 miles but on the way home from a 80 miles trip the other day, it limped 3 times fairly close together. NO rhyme or reason for why it did then and not the first 120 miles or so.

[@protectandswerve]

I would think if it was the turbo and carbon build up, it'd do it all the time once it was hot. I drove it again tonight on a 40 miles round trip and it did NOT limp the whole time. I'm truly baffled.

[@protectandswerve]

And also, if it was the vacuum lines, why not all the time vs. just at freak times like it's doing. ???

[@ollierichards8547]

sorry for the long reply, mine ended up being a clogged up sender unit in the tank. It made the pump draw air through causing bubbles in the fuel line. very easy fix and didnt need a new sender/pump/turbo just needed a very through clean

[@protectandswerve]

Ollie Richards Glad you got it fixed. There are SO many things that cause this. It' so frustrating. I'm SO happy with mine now that it doesn't limp and all the mods / extra power I have now. SO much fun !

[@shruteebhavsar24]

Hi guys I have also boost issues in my Octavia 1.9 tdi vehicle rarely go 120kmps

[@ionutdorgo6187]

Scan the vehicle with vcds or vag-com start from there

[@samcharis8629]

Same problem

[@samcharis8629]

I have skoda Octavia mk1 agr 1.9 tdi. Doesn't go above 120kmps, it seems like it looses power after 3.5k rpm in second gear. It doesn't rev above 2.25rpm on 5th gear. So top speed is near to 120kmph. It sucks.

[@samcharis8629]

Did you get it fixed? cause it's frustrating i can't find a solution.

[@melissamicu6934]

second and third in limp mode but reverse OK a6 àudi

[@duallyking619]

Turbo veins are sticking, best luck is buying a new turbo, just went through it on my 2000 jetta tdi

[@protectandswerve]

Read rest of comments. My issue turned out to be a bad ECU. I modded the car with a new turbo and several other things and the car STILL limped. Used ECU from another car fixed it for good!! Car's been driven lots of miles and been sold over a year ago though. I miss that car.

[@ramoramic8496]

When you changed ECU with used one did you need to something from dealer or just connect and drive? @@protectandswerve

[@protectandswerve]

I believe AARodriguez just Plug and Played! He got it for me and we swap it and it never Limped again. @@ramoramic8496

[@nunonogueira7380]

Bro it's the injector number 3 Needle lift sensor

[@protectandswerve]

Nope...This is a very old vid and fix has been posted many times below... It turned out to be a bad ECU. Once changed, It never occurred again.

[@protectandswerve]

Here's my New Video I put together today about the Mods and the Dyno pulls we did today. It made 163 WHP!!! A 65% increase in power from the stock 99 WHP it did last week. TDI Golf Dyno

[@evelinajurkiene4398]

So, after 10 months, found a solution ? :)

[@protectandswerve]

We Think, Yes. Even all the Mods we did and THOUGHT we had the limping issue fixed, it finally did it again. Well we (AARodriquez.Corp) decided to try a different ECU because my car showed NO timing on VAG-COM. Well after the new (used but known good) ECU, I've driven 1000-1300 miles or so with NO Liming. But it still showed NO timing on VAG with the different ECU. So yesterday we advanced the pump timing a bit and got the timing to read perfectly on VAG-COM. NOW!!!! I think we have it fixed :)

[@reggiecurtis6811]

Have you resolved the problem??

[@protectandswerve]

Lots of explanations here in the comments by me. Yes, it ended up being a bad ECU. Replaced with a known good used one and all was well. Even after a bunch of mods (turbo, tune, injectors, clutch, etc.). Search my TDI vids and you'll see how it was modded. Made 160+ hp and almost 300 ft. lbs. of torque

[@reggiecurtis6811]

Are you open to a phone call?? If so can I have your number?

[@protectandswerve]

@@reggiecurtis6811 Not sure how to give it without doing it publicly, but if you have a question about this vid and fix, you'd be WAY better served to call Mr. Rodridgez at www.tunemyeuro.ocm or www.fixmyvw.com. He's the one that eventually built my car and found the used ECU to swap in.

[@reggiecurtis6811]

Ok thanks I'm having a very similar issue

[@protectandswerve]

@@reggiecurtis6811 www.fixmyvw.com / Mr. Rodrigez will get you fixed up!!

[@MANTOIUful]

Solved problem? How fix ?

[@protectandswerve]

If you read through my comments on here you'll see I ended up modding the car quite a bit but still had the limp issue. Turned out to be a bad ECU. Replaced the ECU with a known good used one and NEVER had the issue again. Sold the car a 1.5 year ago though. Wished I hadn't.

[@samcharis8629]

@@protectandswerve my car doesn't go above 120kmph, did everything like the n75, replaced the turbo, cleaned intake, new air filter, maf sensor. But still doesn't go above 120kmph.

[@aaronhouston1982]

Fix it.yet? Have you tried the water trick? (Mist water into intake) Also have you replaced the vnt valve?

[@protectandswerve]

Not Fixed. Hot temps this time of year is making it worse. Yes, the VNT his been replaced. No clue on the "water mist" trick. Can you give me more details and what that's supposed to help please.

[@averagefamily4272]

Interceptor1255 do not do the water mist trick. you could hydro lock your engine and bend a contacting rod.

[@protectandswerve]

Keith U Wasn't gonna try it anyway. Never heard of it. Thanks though.

[@aaronhouston1982]

I have tried it... But like I said you must do your research... because you need.the motor to be warm. And because of the high temp in a TDI it will evaporate the MIST instantly. BUT I DO STRESS.... A MIST ONLY. or yes. It can cause serious issues.... But again. I have done it.. it seriously evens out my revs. And a bit better gas mileage. I spoke with a local shop known the area for performance vW and Audi diesels. They RECOMMENDED it to me. As well they said I can do that OR they can take off the intake manifold and clean it fully. Hope this in someway helps.

[@aaronhouston1982]

About limp mode. I get that roo and recently found my causes... yes causeS. A) my VNT valve is needed.to be replaced. The cap has blown out over time. B)I have a leak in my boost line... that caused OVER BOOST, causing my VNT to blow out at high pressure.

[@protectandswerve]

TDI Golf Dyno

[@protectandswerve]

Since I'd been wanting to anyway, I decided to just mod this thing for more power :) Here is what all AARodriguezCorp.com did. -VNT17 turbo upgrade -SouthBend Stg. 2 endurance clutch -all new seals and rear main seal -PP764 Injectors (balanced / calibrated) -Malone Stg. 4 Tune -3Bar MAP sensor -EGR delete race pipe kit -New Fuel cut off valve on the pump -All new Vacum lines -replaced to one bad glow plug.

[@protectandswerve]

Even Newer vid of my build by AARodriquez Corp. kzbin.info/www/bejne/n3bEhGOafsSae5I

[@thatguycamers2354]

Interceptor1255

[@protectandswerve]

????? Yes???