P0238 after 156 1.9mJet Remap

Hey all,
I hope someone can help me here. I had my 156 1.9 MJet remapped last week. The results are amazing but I if I push it the engine warning light comes on and I'm reading a code:

P0238 - Turbocharger Boost Sensor A Circuit High

Has this happened anyone else? Any advise on how this is sorted? I've read that it's cause by too much boost (over 22psi??)

That happened to mine, overboost. It was caused by the turbo winding up too quick (it was recently overhauled and must have been moving quite freely) and the wastegate/ variable vanes couldn't reign it in quick enough and would trip the boost sensor out.

I called the mappers and they came back, no questions asked and adjusted the map to bring the turbo in from lower revs and wind up slower. They found another couple of horsepower and smoothed out the power delivery.

Hope yours can be resolved as quick as mine. Your symptoms sound very similar to mine but can't say for sure it's the same problem ... diagnosing things off one post over the internet isn't always that reliable!

In almost all cases it is the solenoid valve that controls the vanes of the turbo.

It costs about 60 Euro.

It might be also a faulty EGR valve...but that depends of the remap you have.

Who did it and what BHP figures they are stating.

Thanks for that. Angel did the remap, I have been talking to them and they're going to look into it. Hopefully it should be straight forward enough!!

Mine wasn't KGB. Maybe I'm a minority.

That was looked at and changed along with the EGR valve, throttle body, boost sensor and the turbo overhaul ... thank you Mr warranty! The only thing that solved it was fiddling with the map.

Originally Posted by rossjmccarthy

Thanks for that. Angel did the remap, I have been talking to them and they're going to look into it. Hopefully it should be straight forward enough!!

Who remapped it?

Mine was an Angel map too, give Nigel a bell, he was good as gold with mine, can't fault him at all. He couldn't make it himself within the next day or 2 so one of the lads (forgot his name) came over from Cardiff, played with the map in the carpark at work and I was back on the road error free.

Originally Posted by OperationAlfa

Who remapped it?

Colm, who came down for N. Ireland to do the map.

I thought it might of been the Irish side.

I'm sure they will sort the problem out for you.

Originally Posted by Dibby

Mine wasn't KGB. Maybe I'm a minority.

That was looked at and changed along with the EGR valve, throttle body, boost sensor and the turbo overhaul ... thank you Mr warranty! The only thing that solved it was fiddling with the map.

A bad map is the last thing I though it might be

But you ended up with a lot of new things on your car for free

Originally Posted by kgb

A bad map is the last thing I though it might be

But you ended up with a lot of new things on your car for free

IIRC Dibby's problems were occuring when it didn't have any remap on it. A remap CURED his problems

But still it was a problem with the map....not the remap

Originally Posted by Pud237

IIRC Dibby's problems were occuring when it didn't have any remap on it. A remap CURED his problems

You got it Pud, took about 8 months of changing bits. Every time I thought I'd cured it I would be fine for a couple of weeks then bleeep bleeep, and it would come back again.

Thought I'd cured it, it was fine for a month or so and that's when I had the map. Everything was going fine and another month on, bleeep bleeep, MCSF error. That's when I had the turbo taken off, sent off and overhauled with suspected sticking vanes/ solenoid and that just made the problem worse once the vanes were free-er. Last resort was to look at the map, it wasn't Angel's fault at all, it was a standard map applied to probably hundreds of cars out there and that cured it, I've been fine for a good 2-3 months now. Fingers crossed!

The map was the cure to the problem in the end, not the cause, and free parts are always good! I noticed the difference in oomph after the turbo overhaul, it would pick up a lot quicker and rev a lot more free.

Have you got a decent free-flowing filter on as well? Standard set-up is far from ideal with the placement of the airbox and all the bends in the pipework.

Nah, standard air box for me, the aftermarket jobs all look pretty pricey for what you get.

At £100 for the airbox, at 1/3rd the cost of the remap I doubt it would get me 1/3rd of the power the remap gave me.

Is there a cheap and cheerful kit out there that does the job just as well? I don't want to pay over the odds for some carbon fibre thing no-one will see and the weight loss makes no difference.

I don't think its the filter so much as all the crap pipework. I was planning to do as jasons did with my JTD, bin the standard intercooler and get put a front mounted one in instead. That way you can mount a K&N cone where the old intercooler is, so it gets nice cold air and no restrictions. Then a straight pipe (MAF in here) straight into the turbo, out the otherside, straight into intercooler, then a 90 bend angled upwards to a pipe straight into the inlet manifold. I can't remember the figures but apparently he made really good gains with this set up

Aren't K&Ns a bit on the oily side and clog up the MAF?

Was thinking about a BMC CDA but they're £150!!

That intercooler and re-routing sounds like a sweet project. Do you have any links to people who have done this before and how easy is it?

Which JTD is your 147....8v or 16v

16v m-jet, started life as a 140bhp before the map.

I'm alright with a spanner, no expert but I'm a water engineer so I understand pipework and losses pretty well - albeit on a slightly bigger scale than an air intake but same principles apply.

Wouldn't mind having a crack at something like this, is it easy to do on the driveway at home or is it a garage job?