New member with big problems...

[maglin]

Hi, maglin from Sweden, registered to see if anyone can get me on the right track.
Feels like I tried everything...

VW Passat TDI 4-motion, -02

My problems started last week when my turbo broke.
Began to smoke and lost all power. It stopped in the middle of nowhere so I decided to drive it to the nearest town. 2km. (this may have aggravated the problem?)

Anyway, got the car to the shop and disassemble the turbo. Send this for repair and they replaced everything except the housing.
While I'm are at the mechanic, I ask him to do a service + timing belt change.

There is plenty of oil in the intercooler but he is able to clean it with diesel and compressed air.

When everything is put together the problems begin.
Starts right away, and runs great at idle.
Total lack of power between 1000 - 2000 rpm.
At 2000 rpm it starts to sound irregularly and black smoke from exhaust. If I hit the throttle very gently I can get it to rev 2800, but then it begins to knock


I suspected the timing belt was installed wrong, but it turns out that it's fitted correct.
Does not seem to be anything wrong with the fuel pump or fuel flow. Rather, it may too be much fuel? (black smoke at 2000 rev).
Also tried without exhaust, if the catalytic converter was clogged with oil. But it made no difference.

Does anyone have any idea?

Starting to suspect my "new" turbo.

/ maglin

[Seatman]

Sounds like there's still oil going through the cylinders, the pipes maybe still have a bit left to get rid of. Try taking off the intake boost pipe and see if it still knocks, be prepared for any oil that might come flying out though lol.

[maglin]

Thx for reply,

If you mean the "pipe" from the inter cooler I already tried that.
There is no change in engine behavior when I take that one off.

Edit.

And there is no change if I disconnect the air mass meter.

[Seatman]

How about the actuator adjustment? Has that been done? You might need to tweak the rod to adjust the boost as maybe it's just not getting enough. Have a look in the faq pages, there's one on adjusting the actuator in there.

[maglin]

Originally Posted by Seatman

How about the actuator adjustment? Has that been done? You might need to tweak the rod to adjust the boost as maybe it's just not getting enough. Have a look in the faq pages, there's one on adjusting the actuator in there.

I have not adjusted the actuator, is this a normal procedure after turbo renovation?
They told me that they replaced everything except the housing, but I don't think they replaced the actuator. (just sand blasted it)
I just assumed the they adjusted the actuator after renovation.

But I have some new clues, today we did a test run without the vac line connected to the actuator.
The problems almost disappeared, or at least changed in behavior. Still knocks, but at higher revs.
(Guess it's because wrong turbo boost)


When the vac line is disengaged, the turbo should give full boost, right?
Or is it the other way around?

I'm starting to suspect there is something wrong with the "new" turbo.

[chittychittybangbang]

watch videos and read this article http://www.myturbodiesel.com/1000q/a...ate-adjust.htm

[maglin]

Originally Posted by chittychittybangbang

watch videos and read this article http://www.myturbodiesel.com/1000q/a...ate-adjust.htm

I watched the video (great video btw), but I don't understand what unit the vac value is in?
I looked in another thread an found the values 3-5in and 18-20in.
Is in, inches of mercury?

I need to convert this to bar or milibar.

If I connect something to measure the vac from N75 solenoid, can I do this when driving to see if the reading changes?

My engine is a AVF, but I guess the vac values is the same?

[chittychittybangbang]

yes, yes, don't know AVF but probably

[Seatman]

Google the numbers for a conversion chart, it's good, you can find converters for everything online.


The avf is just another PD engine chitty

[maglin]

Thanks,

Seems like there is something wrong with the actuator or turbo.
The rod starts to move at 10 in and stops at 15 in.

Think it's strange that there are no error codes or "check engine".
I'll remove the turbo today or this weekend.