Sounds like engine runs out of fuel when pulling 8th gear. New turbo, 2 sets of filters, new fuel lines, fuel pump, boost sensor, check valve and air filter.

Sounds like you have a vacuum leak that gets worse when motor has load on it

Have you checked the PCV system?? If its stuck in the closed position then you will lack power and turbo boost. A vehicle needs 3 things to make it run proper; FUEL,FIRE and AIR. Try that and see if it helps.

I would start with checking the fuel flow at the filter. Twist open the bleed valve on the top of the filter while you are cranking the engine. If fuel is squirting out, then you are getting fuel past the filter. now you will check the injectors to ensure they are getting fuel. You will need a couple of wrenches to break open the line. You can start with the easies ones to access on the driver's side. Be sure you hold the injector tight while you break the line loose from the top. Just loosen it 1 or 2 turns. Crank the motor and see if you are getting fuel to the injector. If you are getting fuel to the injectors, then we have eliminated a fuel problem.

Are your glow plugs cycling correctly? Every time the 6.5 diesel prepares to start, the glow plugs will cycle. The first time the engine is turned on after it has completely cooled off, they will cycle for 10-20 sec depending on the air temp. That clicking sound bothers me like the relay switch for the glow plugs isn't working. How many miles on truck? Have the glow plugs been changed? Has the relay switched been replaced?

The last area to check will be the air intake system. Pull the air filter housing open and remove the filter. Ensure it is clean and no debris got past it and is obstructing the air to the turbo. (My brother had a filter come apart and plug up the turbo.) Don't buy cheap air filters!

Hope this helps. Let me know if you have any further questions.

I have a 94 K1500 6.5 turbo with 282,456 miles on it. Runs like a champ. Out pulls my new Ford.

Russ

Hello.
My suspicion on your problem is a plugged exhaust or slipped crankshaft to camshaft timing.
I'd bet on the exhaust though.
It appears your turbo is doing it's job as it is able to blow off the intake duct.
But if all that pressure can't get out the other end it's bound to do that.
Drill and tap a small fitting into the exhaust pipe behind the exhaust manifold and install a pressure gauge there. Should not be over 1 PSI at idle and not over 2 on throttle blips.
Hope this solves your problem.
If you need more help with this, ask me.

KL

If you have a problem that isn't caused by something obvious, you need a Ross tech VCDS cable. This is a laptop computer diagnostic cable to talk to the car's computer. Without it you cannot do the more advanced tests.
Note about generations - some generations have similar engines: Mk3= 1996-1997 3rd generation Passat TDI or 1996-1999 3rd gen Jetta TDI Mk4= 1998-2006 New Beetle, 1999-2005 Jetta, 1999-2006 Golf, 2004-2005 Passat TDI Mk5= 2005.5-2010 Jetta TDI Mk6= 2010+ Golf TDI
Remember, an engine needs fuel, air, and compression to run. Low power is related to a lack of one of these or a sensor problem making the computer thinking there's a lack of these. Any sensor problem could also be caused by a bad ground or broken/chaffed wire so also check every section of the wiring of the suspect sensor for breaks.
Bad MAF sensor - very likely cause on the mk4 TDI. Not common on the mk3 TDI (1996-1999 Jetta/Passat). Early mk4 MAFs failed often.Error codes normally do not show up with a faulty MAF since the signal degrades instead of going out completely. Through VCDS, checking MAF actual vs. specified at idle, high rpm, and high load will quickly show a bad MAF or other problem causing a low MAF reading.
Clogged intake manifold - carbon buildup chokes the intake manifold, starving the engine of air. Only ultra low sulfur diesel is sold in North America now so there should be much less buildup in the future. Always use good quality synthetic engine oil on your TDI..
Anti shudder valve shut or almost shut (does not apply to mk3 TDI, more for mk4 TDI) - there is a spring loaded valve right before the intake manifold. Newer TDI use an electronic valve and are not as susceptible to sticking. If there is excess carbon buildup, it could shut in a partially closed position.
Clogged snowscreen/air filter - a clogged air filter will starve the engine of air. A clogged snowscreen (large debris air pre-filter) shouldn't block off all air unless the aux-intake flap is also clogged.
Clogged fuel filter - change interval is 20,000 miles but biodiesel use (cleans out old buildup) or bad fuel could clog it early, resulting in fuel starvation. Algae or bacterial growth in the fuel tank could also clog the lines.
Boost leak - a cracked hose or loose connector lets measured air out. No air or major leaks = poor engine running or stuttering. A visual inspection may not reveal all the possible or hard to see spots where leaks can form.
Hose inside ECU (mk3 TDI only, does not apply to mk4 or newer TDI) - this hose leaks and normally sets a check engine light,
Vacuum lines to/from turbo and n75 solenoid - these dry out over time and crack or can rub through. It's possible they are clogged. The n75 solenoid controls the turbo wastegate or VNT vanes with either vacuum or pressure. b4 Passat - on firewall above coolant reservoir, a3 Jetta - on pass side near air box, a4 Jetta/Golf - on firewall above brake fluid reservoir.
Problem with the n75 solenoid, VNT actuator, VNT vanes, or vacuum lines. You should have already checked the vacuum lines, the below test will inspect the entire system. Start the engine and through VCDS, click on "engine"-->"measuring blocks"-->hit "up" until you reach "group 11". Compare Specified vs. Actual MAP. This compares what's actually happening and being observed from the boost sensor (barring a faulty sensor/plug/wire) to boost the computer is requesting (what should be happening). They should be relatively close. If they are far off this normally results in limp mode but it could also be contributing to the problem. If you have a mk3 you have a conventional turbo but you can still use this test to check the n75 solenoid, the wastegate, and vac lines. However, wastegates are much less susceptible to sticking vs. VNT vanes. The videos below show how it works. The lever on the outside is welded to a lever inside the turbo housing. This is how it moves the VNT vanes. See the below videos to see how smoothly and free the lever should move. It should not stick or bind at all. Vacuum is being applied to the can, not pressure.
If the test shows poor response or no response at all, it could be sticky VNT vanes/actuator (mk4 and newer TDI only), The vanes or actuator can stick or fail to function, the lever should move freely.
If the actuator is fine, also check the n75 solenoid and vac lines. The n75 solenoid controls vacuum or boost to the vacuum line going to the turbo wastegate/VNT actuator. To test, apply voltage to the solenoid or swap with a known good unit. If you have a mk4 TDI, you can swap it with the EGR solenoid to test. Also check the plug for corrosion and the wiring harness for chaffing. If those are good, disconnect the VNT actuator rod and move the vanes by hand. If the vanes are stuck then remove the turbo and clean the inside of the exhaust housing to free the stuck vanes.
Faulty injection pump's fuel injection quantity adjuster - these are occasionally set wrong from the factory or after seal replacement. It's also possible the fuel pump's internal quantity adjuster is faulty. Applies to 1996-2003 TDI only or TDI that use a Bosch VE injection pump (not pumpe duse or common rail). Injection quantity should be 3-5 at idle and up to 36-38 at full throttle.

here are all poss causes of check engine light.
Generic Trouble Codes

P0001-P0099 – Fuel and Air Metering and Auxiliary Emission Controls
Code Description
P0001 Fuel Volume Regulator Control Circuit/Open
P0002 Fuel Volume Regulator Control Circuit Range/Performance
P0003 Fuel Volume Regulator Control Circuit Low
P0004 Fuel Volume Regulator Control Circuit High
P0005 Fuel Shutoff Valve Control Circuit/Open
P0006 Fuel Shutoff Valve Control Circuit Low
P0007 Fuel Shutoff Valve Control Circuit High
P0008 Engine Position System Performance (Bank 1)
P0009 Engine Position System Performance (Bank 2)
P0010 A Camshaft Position Actuator Circuit (Bank 1)
P0011 A Camshaft Position - Timing Over - Advanced or System Performance (Bank 1)
P0012 A Camshaft Position - Timing Over - Retarded (Bank 1)
P0013 B Camshaft Position - Actuator Circuit (Bank 1)
P0014 B Camshaft Position - Timing Over - Advanced or System Performance (Bank 1)
P0015 B Camshaft Position - Timing Over - Retarded (Bank 1)
P0016 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A)
P0017 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor B)
P0018 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor A)
P0019 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor B)
P0020 A Camshaft Position Actuator Circuit (Bank 2)
P0021 A Camshaft Position - Timing Over - Advanced or System Performance (Bank 2)
P0022 A Camshaft Position - Timing Over-Retarded (Bank 2)
P0023 B Camshaft Position - Actuator Circuit (Bank 2)
P0024 B Camshaft Position - Timing Over - Advanced or System Performance (Bank 2)
P0025 B Camshaft Position - Timing Over - Retarded (Bank 2)
P0026 Intake Valve Control Solenoid Circuit Range/Performance (Bank 1)
P0027 Exhaust Valve Control Solenoid Circuit Range/Performance (Bank 1)
P0028 Intake Valve Control Solenoid Circuit Range/Performance (Bank 2)
P0029 Exhaust Valve Control Solenoid Circuit Range/Performance (Bank 2)
P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1)
P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1)
P0032 HO2S Heater Control Circuit High (Bank 1 Sensor 1)
P0033 Turbo Charger Bypass Valve Control Circuit
P0034 Turbo Charger Bypass Valve Control Circuit Low
P0035 Turbo Charger Bypass Valve Control Circuit High
P0036 HO2S Heater Control Circuit (Bank 1 Sensor 2)
P0037 HO2S Heater Control Circuit Low (Bank 1 Sensor 2)
P0038 HO2S Heater Control Circuit High (Bank 1 Sensor 2)
P0039 Turbo/Super Charger Bypass Valve Control Circuit Range/Performance
P0040 O2 Sensor Signals Swapped Bank 1 Sensor 1/ Bank 2 Sensor 1
P0041 O2 Sensor Signals Swapped Bank 1 Sensor 2/ Bank 2 Sensor 2
P0042 HO2S Heater Control Circuit (Bank 1 Sensor 3)
P0043 HO2S Heater Control Circuit Low (Bank 1 Sensor 3)
P0044 HO2S Heater Control Circuit High (Bank 1 Sensor 3)
P0045 Turbo/Super Charger Boost Control Solenoid Circuit/Open
P0046 Turbo/Super Charger Boost Control Solenoid Circuit Range/Performance
P0047 Turbo/Super Charger Boost Control Solenoid Circuit Low
P0048 Turbo/Super Charger Boost Control Solenoid Circuit High
P0049 Turbo/Super Charger Turbine Overspeed
P0050 HO2S Heater Control Circuit (Bank 2 Sensor 1)
P0051 HO2S Heater Control Circuit Low (Bank 2 Sensor 1)
P0052 HO2S Heater Control Circuit High (Bank 2 Sensor 1)
P0053 HO2S Heater Resistance (Bank 1 Sensor 1)
P0054 HO2S Heater Resistance (Bank 1 Sensor 2)
P0055 HO2S Heater Resistance (Bank 1 Sensor 3)
P0056 HO2S Heater Control Circuit (Bank 2 Sensor 2)
P0057 HO2S Heater Control Circuit Low (Bank 2 Sensor 2)
P0058 HO2S Heater Control Circuit High (Bank 2 Sensor 2)
P0059 HO2S Heater Resistance (Bank 2 Sensor 1)
P0060 HO2S Heater Resistance (Bank 2 Sensor 2)
P0061 HO2S Heater Resistance (Bank 2 Sensor 3)
P0062 HO2S Heater Control Circuit (Bank 2 Sensor 3)
P0063 HO2S Heater Control Circuit Low (Bank 2 Sensor 3)
P0064 HO2S Heater Control Circuit High (Bank 2 Sensor 3)
P0065 Air Assisted Injector Control Range/Performance
P0066 Air Assisted Injector Control Circuit or Circuit Low
P0067 Air Assisted Injector Control Circuit High
P0068 MAP/MAF - Throttle Position Correlation
P0069 Manifold Absolute Pressure - Barometric Pressure Correlation
P0070 Ambient Air Temperature Sensor Circuit
P0071 Ambient Air Temperature Sensor Range/Performance
P0072 Ambient Air Temperature Sensor Circuit Low
P0073 Ambient Air Temperature Sensor Circuit High
P0074 Ambient Air Temperature Sensor Circuit Intermittent
P0075 Intake Valve Control Solenoid Circuit (Bank 1)
P0076 Intake Valve Control Solenoid Circuit Low (Bank 1)
P0077 Intake Valve Control Solenoid Circuit High (Bank 1)
P0078 Exhaust Valve Control Solenoid Circuit (Bank 1)
P0079 Exhaust Valve Control Solenoid Circuit Low (Bank 1)
P0080 Exhaust Valve Control Solenoid Circuit High (Bank 1)
P0081 Intake Valve Control Solenoid Circuit (Bank 2)
P0082 Intake Valve Control Solenoid Circuit Low (Bank 2)
P0083 Intake Valve Control Solenoid Circuit High (Bank 2)
P0084 Exhaust Valve Control Solenoid Circuit (Bank 2)
P0085 Exhaust Valve Control Solenoid Circuit Low (Bank 2)
P0086 Exhaust Valve Control Solenoid Circuit High (Bank 2)
P0087 Fuel Rail/System Pressure - Too Low
P0088 Fuel Rail/System Pressure - Too High
P0089 Fuel Pressure Regulator 1 Performance
P0090 Fuel Pressure Regulator 1 Control Circuit
P0091 Fuel Pressure Regulator 1 Control Circuit Low
P0092 Fuel Pressure Regulator 1 Control Circuit High
P0093 Fuel System Leak Detected - Large Leak
P0094 Fuel System Leak Detected - Small Leak
P0095 Intake Air Temperature Sensor 2 Circuit
P0096 Intake Air Temperature Sensor 2 Circuit Range/Performance
P0097 Intake Air Temperature Sensor 2 Circuit Low
P0098 Intake Air Temperature Sensor 2 Circuit High
P0099 Intake Air Temperature Sensor 2 Circuit Intermittent/Erratic

get oxygen sensor checked,maybe get tune up see if engine is leaning off properly,could be air flow sensor,but needs sensors to be checked

Hello, I am a Saab technician from upstate new york. It sounds to me that the turbo wastegate rod may be seized to the turbo control valve. The easiest way to try to fix this is to spray penetrating oil on the turbo valve/ wastegate rod and work it back and forth with a pry bar. Many times u can also heat this up with a torch and pray. If those two things don't work than the turbo valve itself is seized into the guide hole machined into the turbo. good luck.

Manufacturer Specific Codes

P1100 BARO Sensor Circuit - Read Our Article on Automotive Circuit Testing For Help With This Toyota Check Engine Light Code

P1120 Accelerator Pedal Position Sensor Circuit - Read Our Article on Automotive Circuit Testing For Help With This Toyota Check Engine Light Code

P1121 Accelerator Pedal Position Sensor Range/Performance Problem

P1125 Throttle Control Motor Circuit - Read Our Article on Automotive Circuit Testing For Help With This Toyota Check Engine Light Code

P1126 Magnetic Clutch Circuit

P1127 ETCS Actuator Power Source Circuit

P1128 Throttle Control Motor Lock

P1129 Electric Throttle Control System

P1130 Air/Fuel Sensor Circuit Range/Performance (Bank 1 Sensor 1) - Read Our Article On Oxygen Sensor Codes For Help With This Toyota Check Engine Light Code - More Related Information

P1133 Air/Fuel Sensor Circuit Response (Bank 1 Sensor 1) - Read Our Article On Oxygen Sensor Codes For Help With This Toyota Check Engine Light Code

P1135 Air/Fuel Sensor Heater Circuit Response (Bank 1 Sensor 1) - Read Our Article On Oxygen Sensor Codes For Help With This Toyota Check Engine Light Code - More Related Information

P1150 Air/Fuel Sensor Circuit Range/Performance (Bank 1 Sensor 2)

P1153 Air/Fuel Sensor Circuit Response (Bank 1 Sensor 2) - Read Our Article On Oxygen Sensor Codes For Help With This Toyota Check Engine Light Code

P1155 Air/Fuel Sensor Heater Circuit. (Bank 1 Sensor 2)

P1200 Fuel Pump Relay Circuit

P1300 Igniter Circuit Malfunction - No. 1

P1305 Igniter Circuit Malfunction - No. 2

P1335 No Crankshaft Position Sensor Signal - Engine Running

P1349 VVT System

P1400 Sub-Throttle Position Sensor

P1401 Sub-Throttle Position Sensor Range/Performance Problem

P1405 Turbo Pressure Sensor Circuit

P1406 Turbo Pressure Sensor Range/Performance Problem

P1410 EGR Valve Position Sensor Circuit Malfunction - Read Our Article on EGR Valve Codes For Help With This Toyota Check Engine Light Code

P1411 EGR Valve Position Sensor Circuit Range/Performance - Read Our Article on EGR Valve Codes For Help With This Toyota Check Engine Light Code

P1500 Starter Signal Circuit

P1510 Boost Pressure Control Circuit

P1511 Boost Pressure Low

P1512 Boost Pressure High

P1520 Stop Lamp Switch Signal Malfunction

P1565 Cruise Control Main Switch Circuit

P1600 ECM BATT Malfunction

P1605 Knock Control CPU

P1630 Traction Control System

P1633 ECM

P1652 Idle Air Control Valve Control Circuit

P1656 OCV Circuit

P1658 Wastegate Valve Control Circuit

P1661 EGR Circuit

P1662 EGR Bypass Valve Control Circuit

P1700 Vehicle Speed Sensor '2' Circuit Fault

P1705 Direct Clutch Speed Circuit Fault

P1765 Linear Shift Solenoid Circuit Fault

P1780 Park/Neutral Position Switch Malfunction (Only For A/T)

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Check out all your air hoses and clamps and check the turbo itself to make sure it spins freely. (Engine not running)