I've had to take a tangential walk away from the HPFP rebuild project because it would seem that my Mini is not completely ok. For those who want the short version, I had a pile of HPFP symptoms and several dead or dying HPFPs (confirmed via graphing fuel pressure data), accompanied by all the usual symptoms, including a half-engine light carrying CCID-029.

At the end of all that I finally laid hands on a brand spanking new Genuine MINI (not aftermarket) HPFP. And it has NO problems at all. Zero.

All good right? Wrong.

Get on a slight grade, and give it that gentle amount of gas you give it when you want to keep your speed uphill, or maybe pass someone but not VROOM I AM PASSING YOU pass someone, and... boom. Half-engine light, CCID-029... and *no* OBD trouble codes, pending or otherwise, and *no* loss of fuel pressure of the kind clearly documented in real-time scan data with the iffy HPFPs. No limp mode, either. EVER.

At next start, once you kick the RPMs up to about 3K for more than a blip and the half engine light clears. RELIABLY.

So off I went to chase down other possible causes of the CCID-029. First thing I noticed -- the code was sometimes throwing on cold start, before the vehicle was even put into gear. Got to talking to some experienced Mini techs and they suggested a vacuum leak might be in play. My Mini was bought at 144K miles and everything rubber and plastic under the hood is generically suspect (I had a plastic coolant tee rip into two like wet Rice Krispies while changing the oil). Additionally, my oil cooler gasket was leaking.

So I had the oil cooler gasket leak fixed, the turbo oil lines changed out for stainless steel braided since we were in there tearing things up, and I had the vacuum hoses replaced. Period.

Result: car is, uh, "vroomier." Who knew? But... wait for it...

Definitely less frequent and harder to reproduce, and hasn't turned up on cold start (yet), but still able to land the half-engine light and CCID-029.

Ok. The last thing I knew about was that the rightmost airbox screw (the one next to the air duct) wasn't bolting things down because the prior owner had stripped the hole. Off to projectland. Filled it with an epoxy, drilled a new pilot hole. Cleaned and oiled the K&N air filter that was on the car when I bought it, just for good measure. Put it back together. Airbox tightens up GREAT.

Result: car is, definitely, and oddly, even more "vroomier." Seriously, this thing wants to go bungee jumping or something. Who knew? But... wait for it...

Still and again, even *less* frequent and harder to reproduce, and hasn't turned up on cold start (yet), but still able to land the half-engine light and CCID-029.

So I've got nothing. Engine is ridiculously clean. No leaks of any kind. Vacuum hoses replaced. Airbox and intake ducts are tight. Maybe there's some other way to have a vacuum issue (including the pump I guess) but I can't find any *obvious* signs of an issue.

Except for 8 codes in the "secret menu" accessible through the tachometer.

Here's the list. Anybody have any ideas what these mean? What component they point to? Something?

ERR01 AC3Ch 200070F57A00
ERR02 A3A9h 200070F58200
ERR03 9319h 200070F57B00
ERR04 931Ah 200070F57B00
ERR05 A3C1h 200070F57700
ERR06 A3B4h 200070F58E00
ERR07 931Bh 200071307F00
ERR08 931Dh 200072074900

Note that there are *no* OBD trouble codes stored, pending or otherwise, that are viewable with a garden-variety OBDII scanner. I have been watching for these in real time as well as when the car is on but the engine is not running.

If I can nail this down I can get back to turning my Mini into an HPFP rebuild guinea pig

 

Update: Looks like I have turbo issues. A scan at the dealer revealed the following, both with mileage from today's trip. They appear to correspond, based on mileage (there are no timestamps) roughly with my latest CCID-029s, which happen pretty much on every drive. The 002C57 was almost definitely a direct correlate with a CC-ID 029 that lit up 6 miles into a drive today.

002C57 Charging pressure control, plausibility Pressure too low
002C91 Blow-off valve, mechanics: Suspicion that blow-off valve is jammed open

I'm new to turbochargers but hey, if I can dissect an HPFP and put it back together again successfully, I can fiddle with a turbo. I'm off to replace the BOV aka diverter valve aka pain in my neck.

Oh, I already know about the extended warranty on the turbo. It's 10 years/120K miles; I'm at less than 10 years, but well over 120K miles. Already looked into it, dead end. :/

 

Does anyone know the proper torque spec for the 3 bolts securing the diverter valve (part name) / blow-off valve (part name the code calls it) / recirculation valve (what the Bentley manual calls it) to the turbocharger?

I have the Bentley manual but I'm not having any luck finding it in there, and Google is not my friend so far.

 

Update: Replacement of the diverter valve had no effect whatsoever. Guess the "002C91 Blow-off valve, mechanics: Suspicion that blow-off valve is jammed open" has the wrong suspicion

Mini is going to the dealer tomorrow for hands-on diag.

 

Update: wastegate is fine, pressure converter valve is fine, but whatever is going on is "inside the turbocharger." Probably a bearing (best guess) sooooo...