That - I've got no power from the turbo question (again!)

[leigh195]

Evening All,

First post so I'll apologize for no introduction and the typical can I have help and leave again type behavior.

The story
3 weeks ago the turbo begins making a lot more noise but no smoke, leaking oil.

Works over the next 2 weeks until last tuesday.

Driving up the M3 on occasions black clouds would appear but not produce for a long time with no loss so just assumed slight overfuelling. Worked my shift and drove home. On the way black smoke was ******* out the back like nobodys business. Take it easy and still have boost.

Stop for fuel and as accelerating on the slip road. Large cloud of black smoke and loss of power half way along. Carry on going to home taking it easy and struggling to go forwards anywhere.

Got car home done some 'tinternet diagnostics' and spoke to a VW mechanic mate who suggested EGR valve. Cleaned put back together. Slight improvement 1-2but not alot at all in 3-4&5. Turbo still makes noise and produces black smoke until car warms up. Also noticed that alot of oil residue built up around the passenger side foglight with no leak

I'm trying to locate the loose turbo pipe and hope that helps but otherwise at a loss. Due to cuts and various things I can't afford a garage or to get a diagnostic so crystal balls at the ready!

Any suggestions or help greatly appreciated

car is a 52 plate 1.9 TDI SE 130 bhp

[snapdragon]

Disable the EGR valve in case it is stuck open or being held open by faulty N75, being dirty would help prevent this, rather than cause it.
Pull off the EGR's vacuum pipe and plug it with a ball bearing or similar.

[Peter D]

Can you describe the noise. If revved when stationary can you see the turbo actuator moving. Remove the acuator vacuum pipe at the solenoid and suck on it to see if it is leaking. What engine code do you have, may be AWX, it is on the ID label in the spare wheel bay. Regards Peter

[leigh195]

SD -I'll give that one a go tomorrow when I can get stuff at work.

PD - AWX is the engine code. Is the turbo actuator hidden under the plastic bit of the engine and surely you shouldn't be able to see it move? And as per original post I can't afford to get it in the garage for anything

Apologies for the kick yourself dumbassedness. I can fix things so long as I know where I'm looking.

[fjtwelve]

N75 boost control and or duff temperature sensor will cause black smoke.. N75 sits on the turbo, approx shoe polish tin size, has a rod coming out of the bottom of it to an arm on the turbo, vacumn inside N75 causes rod to move, operates arm, alters vane angle inside turbo. don't know where your temp sensors are. I'd guess that the improvement after cleaning the EGR is because it was clagged up after 9 years and is now working almost properly again. The inside of your inlet manifold is probably full of soot and cleaning that out would also make a noticeable difference. I did it on the 1.9TDI Passat i had and livened it up somewhat.

[leigh195]

The oil temp sensor hasn't worked in 5 months since my heater matrix bust. Since January I've had no climate control (although the unit lights up) no OAT and no oil temperature reading. So seems strange it's only doing it now.

I said to a mate it would be good to have a strip down and clean the whole thing through so it's in the pipeline. I'll have a look at the turbo and see what happens then.

Thanks FJT

[Peter D]

N75 is the electrical solenoid valve. The shoe polish tin is the vacuum actuator above the turbo. N75 controls the vacuum to the actuator.
OP oil temp and coolant temp are completely different. Regards Peter

[fjtwelve]

As ever Peter D is correct. I've been away and done some research to understand. I have had 2 problems over the years. One was with the vacumn actuator and one was with the solenoid and they were both referred to me as "the N75". Sigh. Moral if you want to know something ask a man who knows.
I was referring to air temperature not oil temperature.

tdiclub.com may be able to help you, for instance look here http://pics.tdiclub.com/data/517/LimpModeDiagnosisGuide.pdf

[leigh195]

Cheers for the help. I imagine it'll be another weekend slaving away under that damn bonnet! I'll update when I get a chance

[leigh195]

Discovered a sodding great chunk of the turbo intercooler missing and a gasket hanging out where it should be. Any tips on repairing such things? Just temporarily until I've sourced a new one anyway.

I've got a Modine replacement in there at the moment so no good part no. to go on other then this; 8E0 145 805 F. Could someone advise if I can get one of the ones with this part no. 058 145 805 A to fit?

Engine code is AWX
Year 2002
1.9 TDI

Thanks in advance
Leigh