[Solved] Audi a4 b7 2.0 tdi BRF 2007 - SPARK at 1800 rpm, turbo not supercharged

Hello
as a mechanic for 16 years, I am no longer in my profession, I'm stupid to write
Audi a4 b7 2.0tdi BRF 2007 patient without DPF

It started with the error of exceeding the boost regulation, of course, power drop, fierce geometry of the compressor, it was gently grabbed from the bottom on the cold engine with barely perceptible resistance, the car to the mechanics flooded the compressor from the back, and they were definitely starting the regulation because the "seal" was broken. From then on, the car jerks between 1800 and 2100 revolutions, it is a very strong jerk with a gentle throttle about 5-15%, when pressed to the floor the problem disappears. The car was returned to the workshop, they replaced the EGR and the same. So I decided to take a look at what is happening, the more so that in a few days I am going on vacation and I cannot afford to have the car sitting at the mechanics for another week.

And now my observations after inserting the metal plate in the RGR, the car does not catch the error, it goes ok, when the egr error pops up, the power drop and you can turn up to 3,000 revolutions, with a drilled 12mm egr plate, it will tear, but less the power drop.

I checked the turbine blades are ok, no play, it turns loosely, the turbine bar is loosely, whether it is fired or not ok

A strange thing when reading the boost charts, after starting the engine, the set pressure value is about 1050 and the resulting pressure is 950 (as much as atmospheric pressure), i.e. turbo at rest and it would seem that it is with a delicate gas (turbo not supercharged) but as I step down after gas it is overloaded. If I wrote something wrong, correct it in my time, the turbo only turned on with no pressure changes

I was thinking about the gas resistor but after reading about the symptoms and they do not match
I do not like the EGR chart, but it is new, so it would appear that the flow meter is distorting the result

No errors
I enclose a movie of driving with some parameters



[movie: dd1e79cb47] https://filmy.elektroda.pl/66_1530362723.mp4 [/ movie: dd1e79cb47]

It's hard to diagnose what it can be at a distance, but maybe I'll tell you something. I had a similar problem in 1.9 on unit injectors, the car did not go on the turbo computer, does not get up. I did not move the EGR, but the first shot went to the geometry of the turbine, I wanted to pull it out, but they always taught to start with the simplest things and so I was looking for the one-way valve to fall, after replacing the car, it flies as before. The second thing they moved the barbell adjustment, I wonder if they set it how it should be, the third thing with this EGR, they showed you the old one, that they also probably replaced some one-way valves, you need to check if they do not release in both directions

Ok, thank you all for your help, the problem is solved (I hope) in the evening when I twist and drive, I will describe it, maybe it will be useful to someone

Added after 1 [hours] 40 [minutes]:

Once again I watched the recording calmly and came to the conclusion that the turbo is not recharging and this overloading is nothing more than the acceleration of the rotor in relation to the set pressure, so slowly after one revolution I started to shorten the adjustment, but something strange every time the indications on the chart are unreliable some strange no having nothing to do with the regulation made. when I was already tightening the adjustment to the maximum and further the graph showed that the turbo does not work at idle, it surprised me a bit, I detached the intake pipe from the throttle and at idle it turned out that the turbo was blowing, so since the computer showed 951 and so almost 1.5 thousand revolutions then slowly increased and the atmospheric pressure according to ecu was also 951 so the sensor readings must have been wrong or I was reading the data wrong. I have no idea which sensors are responsible for checking the pressure in the intake manifold, but what first came to my mind is that one of the air flow control elements is a fish pass, without thinking much, I just unplugged the plug, returned the turbo adjustment back and looked at the graph, revs about 900 set pressure 1020 boost pressure 995 so something moved I add RPM pressure follows the set graph quite nicely, I sit down to the car, drive, the car does not jerk, it can push back into the seat as much as 2.0 tdi can. But for everything to be done, I put the old EGR back by mechanics and interestingly the old car also goes ok. I wonder if on Monday to visit mechanics with this egr it cost PLN 570 + PLN 100 replacement (or something like that)

You can also check the flow with an ordinary multimeter, if necessary, remove and rinse with a brake disc cleaner, spray and wait until I evaporate, and the flow is four pins ground, + 12V, signal and power supply from the 5V driver, on the engine running, unless you have 5 pins, then then there is still temperature. As for the sensor, you may not have it in the collector, only in the IC, as it is, for example, in 1.8T or on the pipe from the IC to the collector, e.g. in 1.9, you need to look carefully. EGR, give back PLN 600 on foot, but you will buy a flow when yours fell

Once again I watched the recording calmly and came to the conclusion that the turbo is not recharging and this overloading is nothing more than the acceleration of the rotor in relation to the set pressure, so slowly after one revolution I started to shorten the adjustment, but something strange every time the indications on the chart are unreliable some strange no having nothing to do with the regulation made. when I was already tightening the adjustment to the maximum and further the graph showed that the turbo does not work at idle, it surprised me a bit, I detached the intake pipe from the throttle and at idle it turned out that the turbo was blowing, so since the computer showed 951 and so almost 1.5 thousand revolutions then slowly increased and the atmospheric pressure according to ecu was also 951 so the sensor readings must have been wrong or I was reading the data wrong. I have no idea which sensors are responsible for checking the pressure in the intake manifold, but what first came to my mind is that one of the air flow control elements is a fish pass, without thinking much, I just unplugged the plug, returned the turbo adjustment back and looked at the graph, revs about 900 set pressure 1020 boost pressure 995 so something moved I add RPM pressure follows the set graph quite nicely, I sit down to the car, drive, the car does not jerk, it can push back into the seat as much as 2.0 tdi can. But for everything to be done, I put the old EGR back by mechanics and interestingly the old car also goes ok. I wonder if on Monday to visit mechanics with this egr it cost PLN 570 + PLN 100 replacement (or something like that)