stevefoster Posted July 19, 2005 Share Posted July 19, 2005 I've got a 2002 Passat TDI PD 130. Up until now it been fine. 84000 miles. No smoke. I didn't use the car over the weekend. My wife did but she might not see if the rear bumper was ablaze so that's no help. She only made two local journeys. Monday morning, lots of smoke under acceleration from 1900 rpm to ~2900. Bewlow 1900 or above ~2900, no smoke all the way to the redline. Looks like sooty unburnt diesel or oil getting in there somehow. I've injector cleaned her and the fuel is ok as far as I know as it suddenly started doing it mid tank. I've tried revving her repeatedly to deglaze bores / clean things out - no change. Performance seems unaffected. Fuel economy might be down but I've been booting it so may be not. I've checked all the miles of hoses around the turbo, inlet side etc. can't see any splits or hoses off. There's oil around a little actuator that opens a butterfly in the inlet air side to the turbo. It must have come up the vacuum or pressure pipe that actuates it, It moves when running to the valve / butterfly is actuating. The pipe to it originates near the front base of the turbo and goes through another elec operated value thing. There are also oil deposites / collecting on the outside of the bottom pipe to the intercooler? The latter I can confirm has been like that 10 months with no issues. This raised my curiousity at the last oil change but as all was fine no need to worry about it. It's not overfilled with oil either... Any one any expereince of this type of problem and it's resolution? I was hidding from a police car behind us ahead of a builders van hoping he would not twig it was me... It's that bad. Hants (north) / Berkshire club here Area meeting pics here My Racing here Edited by - stevefoster on 19 Jul 2005 16:40:45 Edited by - stevefoster on 22 Jul 2005 10:33:07 Link to comment Share on other sites More sharing options...
Dirty Den Posted July 19, 2005 Share Posted July 19, 2005 Sorry to hear of the problems Steve - if I can help in anyway, or you need a lift etc, give me a shout Den http://www.dens7.co.uk Link to comment Share on other sites More sharing options...
jingars Posted July 19, 2005 Share Posted July 19, 2005 I own a Ford Galaxy 115PS TDi. This is also a VW PD engine. I bought a chip via ebay that would give an extra 20HP. This is achieved via a re-map of the fual-air mixture; nothing else is touched. Having plugged this in it does feel as if the van has more "oomph", but it does chuck out more smoke when accelerating hard. It is burning no oil at all - the oil level hardly drops between services. I will have a look on the Ford TIS CD (another ebay purchase) and see what it suggests for excessive unburnt fuel. I know what the fix for mine is - remove the after-market chip! Link to comment Share on other sites More sharing options...
Graham Perry Posted July 19, 2005 Share Posted July 19, 2005 I don't know much about VW units, but am on my 4th diesel car and have read a lot about them and worked on a few larger simpler (truck) units over the years. Mid range smoke is often associated with incorrect functioning of the exhaust gas recirculation valve on many turbo D's among other possible things such as MAF sensor failure, dirty air filter etc. The VW's work on a different principle to other manufacturers so this EGR thing may not be relevent in this case, but I would put it on the list of things to have checked. Don't swalow the old "its the pump or its the injectors" routine as these are often the least likely things to go wrong these days and sadly about the most expensive to fix. Link to comment Share on other sites More sharing options...
Rob Walker Posted July 20, 2005 Share Posted July 20, 2005 Sorry to say but it sounds like the seal has gone on the bearing within the turbo. Mine failed without much warning on the way home from Silverstone last wednesday on my 320D BMW. Look on line there are plenty of companies doing exchange units Turbo Technics 01604 705050 BTN 01895 466666 are the best. Link to comment Share on other sites More sharing options...
stevefoster Posted July 20, 2005 Author Share Posted July 20, 2005 Thanks for the advice. Progress:- On inspection, I had some oil in my turbo to intercooler pipe It's always been oil around that area from the 1st service I did, 15000 miles ago when I first got the car. It seems that any breathed oil from the camcover looks like it goes that route, pressured through the intercooler and then gets burnt. I cleaned that out best I could. I have not overfilled it with oil. I do run it at the full mark, drained some out (down to 3/4) to see is that made an improvement. Checked all hoses and pipes. All ok. I put on a new air filter and test drove it. Similar at first but after warming it up I took it to 200 rpm below the redline repeatedly. Above 3000 it's fine. You can sit at 4300 with no visible smoke at all. I did this the entire length of the dual carriage way from Bagshot to Bracknell... Once you get past 3000 even with foot planted up to 4300 there is no visible smoke. I would think this means the turbo oil seals are ok? The assume the turbo is still working above 3000 and harder than below but I'm no Turbo Diesel expert. The other thing I have noticed that wasn't there before is a whoosh or air / breathing noise right near the drivers side firewall when requiring hard work from the engine at 1900-2500 rpm, higher up the noise vanishes. Not done that before. Power is good. Econ? er don't know, but the instant read out seems to be ok. I had a mass-air meter go on the last Passat. That was not a PD. It was just gutless, no smoke. But they could be very different... Current plan is to rev drive it some more to clear it out. Put a new tank of BP or Shell's finest in it (its on Sainsbury's at the moment) and then if no better seek help from a Diesel Injection Specialist. Anybody know if the Diesel Specialist SAS in Guildford on Slyfield estate is good? I've heard reports that nearby VX and VW farm diesel work out to them at times... Hants (north) / Berkshire club here Area meeting pics here My Racing here Link to comment Share on other sites More sharing options...
stevefoster Posted July 20, 2005 Author Share Posted July 20, 2005 Right, Diagnosed. By me. Small split in the pipe coming out of the Turbo to the steel pipe that leads under the rad to the other side of the front where the intercooler is! Bar$tard to find as it was wrapped in heat shielding stuff. Chuffed not. Get a new part tomorrow and connect up and see... Save a packet no doubt... What to spend it on? Hants (north) / Berkshire club here Area meeting pics here My Racing here Edited by - stevefoster on 20 Jul 2005 21:41:54 Link to comment Share on other sites More sharing options...
stevefoster Posted July 21, 2005 Author Share Posted July 21, 2005 New part not available from German Swedish French, so had to buy OEM. £72 😳 Nice bit of pipe though. I dread to think what the long ones cost... Car is perfect now. No smoke and pulls like a train. Well it is a small diesel train isn't it 😬 Hants (north) / Berkshire club here Area meeting pics here My Racing here Edited by - stevefoster on 22 Jul 2005 09:45:42 Link to comment Share on other sites More sharing options...
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