golf 1.9tdi heavy black smoke

[gerleech]

Hi, My first post. I have a 1999 golf tdi that has a engine problem. It smokes heavy black sooty smoke, idle`s rough, diesel knocks on throttle.
Have checked cam belt timing and crankshaft sprocket. Have codes of P1561 QUANTITY ADJUSTER CONTROL DEVIATION, P1563,P1354,P1247,P1256,P1144. The car will not rev up, not possible to drive. Any ideas please,

[Crasher]

What is the engine code, AHF? So codes

17969 (P1561) Metering adjuster -N146 Control difference

17971 (P1563) Metering adjuster -N146 Lower stop value

17762 (P1354) Modulating piston movement sender -G149 Electrical fault in current circuit

17655 (P1247) Needle lift sender -G80 Open circuit/short to positive

17664 (P1256) Coolant temperature sender -G62 Open circuit/short to positive

17552 (P1144) Air mass meter -G70 Open circuit/short to earth

Do these codes clear and all come back or is this the first read?

[gerleech]

Hi Crasher, Sorry for late reply. Indeed it is a AHF, when I clear the codes only P1561 comes back.
Thanks.

[Crasher]

The two most likely causes of that fault code are a defective injection pump or a wiring fault. Get the engine hot (over 85 degrees C) and go into Measuring Blocks 08 Display Group 001. In Display Zone 03 you should see a voltage of between 1.3v and 2.1v. If not, disconnect the 10 pin pump plug and measure the resistance between contacts 1 & 2 and then 2 & 3, the resistance should be between 4.9Ω and 7.5Ω

http://i222.photobucket.com/albums/dd20/Crasher1964/TDI10pinplug.jpg

[gerleech]

Hi Crasher, I thought it might be the injection pump and I already got a second hand pump to try out. But no success, the same
problem presents, excess smoke and timing all over the place.
I have checked the resistance at the 10 pin pump plug as per autodata but again it was ok.
Is the control unit (ecu) located under the wipers on the bulkhead and is it prone to water ingress ?.
Thank you,

[Crasher]

Black smoke says too much fuel and not enough air, you may have a boost leak. I had this from another garage the other day, black smoking and poor performance on a 130 TDI Golf 4. They pulled all the turbo system off, stripped and cleaned the turbo, everything. They were talking new ECIU as well (yes it is under the windscreen and yes they can let water in) but I got them to bring it down and let me do a leak test using my VAG boost system leak tester. As soon as I put it on, one of the boost hoses (the one from the turbo to the inner wing link pipe) opened up where it had split but on realising the pressure the split was invisible. What fault codes are you getting?

[gerleech]

Hello Crasher, the last codes I recorded were P1563 Fuel quantity adjuster, P1345 Fuel Quantity position sensor, Unfortunatly I cleared the latest codes to see what would return, no codes returned yet,I should have noted them first but didnt, from memory the related to the injection pump. Its no understatment about the black smoke there are particules of soot on the workshop floor and the surrounding area. The only difference with the change of inj pump is that now the engine will rev up but with lots of smoke, the other pump refused to rev with violent diesel knock and the same smoke. Any thoughts.
Gerry.

[Crasher]

So no codes at the moment? Have you fitted a new genuine dealer supplied Air Mass Meter?

[gerleech]

Hi Crasher, No I haven`t , because I did not think the symptoms pointed to it. Normally a duff airflow meter will just result in a severe lack in performance, but I am not sure with VW, If you think I should change it I will. But I will first of all check out the turbo boost as you listed in your previous post. Thanks,
Gerry.

[VinnyTheGolfMan]

Welcome, hope you get your problem sorted.

[gerleech]

Hi all, the story so far!. I have checked the continuity between the inj pump plug to the ECU plug and found to be ok.
There seems to be a problem with the ECU itself sometimes the engine will idle irratically at between 1050 & 1400rpm and I see on measuring block 001.........mod. piston displ 0.68 to 2.13v and injection quantity 0.1 to 3.8 mg/H at the same time lot of dence sooty smoke.
If re started the engine sometimes idles irratically at 850 to 945rpm and 001.........mod. piston displ 1.10 to 2.40v with injection quantity 1.4 to 14.0 mg/H and the sooty smoke is gone replaced by less above normal diesel smoke.
Is there any check to be made on the ECU ?.
Gerry.

[Zecolleman]

I have the same proplem with my vw caravelle. Do you know if I can reach gerleech? Or maby you can come up with some idea. here is the car running on youtube 1999 VW CARAVELLE BLACK SMOKE.mp4 - YouTube (http://www.youtube.com/watch?v=r466eTl5HOg)