Gttdi 2002 - very smokey on revs

[CIARA_GTTDI]

HI guys, i'd really appreciate some help asap. I got a second hand gttdi from a dealer, 1.9 130 bhp one.. its a rocket, but i have mu concers, on soft as well as high revs, i get black smoke from the rear, quite a lot some times. i release the acc, it stops, i put it on again, it comes back, i go up a gear - it goes away..

on start up its perfect, low revs its perfect. but if you take off or go through the gears lazy, its black smoke...

i did a quick search online - "check the oil turbo gasket??" is that an idea? i'm due an mot, i have services for the next few months from the dealers, but i think they are taking the p-p out of me because i'm a girl.

can anyone help point the finger on the problem? diesel = smoke, but not lots and lots.. i've seen other ones and they are pretty clear, so something has gone some where?

injectors? that'd be silly... turbo? its 65k+ miles on it.. any questions, just ask!

Please help.

[martin1810]

Ask in vag-com section to see if anyone nearby can do a code read for you. Failing that take it to a local garage and ask for a code read. Put the code results on here and someone will help you.

[M53494]

Could be a problem in the air pipe from the intercooler to the turbo. Either a spilt/crack in the pipe, or one of the joints isnt sealed properley or has come adrift.

[CIARA_GTTDI]

thanks guys, thats 2 things to look for.. i'm guessing something leaking into something else alright, but why would a crack in the intercooler pipe leading to the turbo cause black smoke?

just so i can understand - but everything you guys point out i'm going to print. i want this repaired! they sold me the car, they can fix it!

[M53494]

thanks guys, thats 2 things to look for.. i'm guessing something leaking into something else alright, but why would a crack in the intercooler pipe leading to the turbo cause black smoke?

just so i can understand - but everything you guys point out i'm going to print. i want this repaired! they sold me the car, they can fix it!

In a 'non technical/professional way', the leak in the intercooler to turbo pipe causes lots of black smoke because of over fueling. This being caused by air leaking out of the pipe, so there isnt as much air getting into the engine as what the fuel system thinks there is.

It could be the pipe just behind the front off side wheel, where the plastic joins the alluminium section. The locking lugs on the pipes are prone to wearing and so the horse shoe shaped spring clips dont do their job... or fall out!

I saw a Landrover Discovery diesel with a split in its intercooler to turbo pipe once - it was like an old factory chimney belching thick black smoke!

[GtTdi 365lb/ft]

HI guys, i'd really appreciate some help asap. I got a second hand gttdi from a dealer, 1.9 130 bhp one.. its a rocket, but i have mu concers, on soft as well as high revs, i get black smoke from the rear, quite a lot some times. i release the acc, it stops, i put it on again, it comes back, i go up a gear - it goes away..

on start up its perfect, low revs its perfect. but if you take off or go through the gears lazy, its black smoke...

i did a quick search online - "check the oil turbo gasket??" is that an idea? i'm due an mot, i have services for the next few months from the dealers, but i think they are taking the p-p out of me because i'm a girl.

can anyone help point the finger on the problem? diesel = smoke, but not lots and lots.. i've seen other ones and they are pretty clear, so something has gone some where?

injectors? that'd be silly... turbo? its 65k+ miles on it.. any questions, just ask!

Please help.

It could be something as simple as a dirty EGR pipe. The EGR (exhaust gas recirculation) valve sends spent exhaust fumes back into the engine to reduce Co2 output at low revs. So when you lean on the accelerator in high gears, or when you start to accelerate from slow idle traffic, you get a dark 'sooty' discharge as the revs pick up. This is the effect of putting air through the engine twice (or more!). The valve closes as the revs pick up, so a higher percentage of 'fresh' air is going into the engine, therefore a cleaner exhaust gas is expelled as the revs pick up.

The EGR pipe and inlet tend to get grimy so cleaning it helps to avoid more 'gunk' going into the engine. Its not a big job to do and would probably be a good place to start troubleshooting.

As said it may be a perished intercooler pipe, you may notice a small drop in performance and / or economy as well as the thicker constant black smoke.

[CIARA_GTTDI]

Thanks a million for the pointers lads. I got it in for a check. the guy found a small hole in the intercooler!

Nice shooting : M53494

Tell me something, i think he is trying to take the p### ? I got the car in march - they wanted to charge me for parts and work etc.. sure if it has a years parts and work, sure they obviously sold me a bad car? needing parts.

I told him he can go and swing, they sold it, they repair it within the year!

cowboys me thinks. I recall i drop the car and on the first day it had the smoke, so it was sold like this..

.....either way, can any of you tell me, what small add ons can i do to boost up the car? without going mad.

it's 130bhp, what little things can be done? I heard they can be open to 200+ ? 1.9 gt tdi.. 2002 model.

[GtTdi 365lb/ft]

Thanks a million for the pointers lads. I got it in for a check. the guy found a small hole in the intercooler!

Nice shooting : M53494

Tell me something, i think he is trying to take the p### ? I got the car in march - they wanted to charge me for parts and work etc.. sure if it has a years parts and work, sure they obviously sold me a bad car? needing parts.

I told him he can go and swing, they sold it, they repair it within the year!

cowboys me thinks. I recall i drop the car and on the first day it had the smoke, so it was sold like this..

.....either way, can any of you tell me, what small add ons can i do to boost up the car? without going mad.

it's 130bhp, what little things can be done? I heard they can be open to 200+ ? 1.9 gt tdi.. 2002 model.

Normally cars from a dealer come with a 3 month parts only warranty, unless you pay extra for a 12 month warranty, so as much as it is a **** take, you'll get no joy getting the work done for free. If it was smokey before and you didn't take it back, he's unlikely to be sympathetic. Hes more likely to shave a layer of rubber off your tyres and put it on another! Its not a difficult job to do yourself if your handy with spanners...!!!

Ok, mods to improve performance, ill put them in order of cost / effectivness. If you start at the beginning and still want more power, keep going until you run out of: space on your licence for more points, cash, free time, skin on your knuckles, milk for your tea. There are obviously loads of mods you can get, but you can do lots and get no-where so these are the 'better' mods to do.

Air filter - either a panel filter which will let your engine breath a bit easier and give you a bit of mpg / or you can get an induction kit which is more expensive, but gives you some grunt which you'll notice. It also gives a sporty sound and bit of mpg.

Remap - Tells the engine to give more of a power output than standard. By upping the power / turbo boost you may wear engine parts such as the turbo quicker, but the engines are usually so bomb proof that you'd hardly notice the wear (unless you constanly thrash the car hardly, which will be easy to do with re-maped car!). It can cost a few hundred quid upwards. Id avoid the 'plug-in' boxes that you can get for your ecu, mainly because I dont know what they drive like. It stands to reason that if somone is re-maping your car and they need to put the car on a rolling road and spend some time with it to gain the best results possible. If you buy a box and plug it in, im sure you'll get a result, but its not going to be the same as proper job. (dont forget your silicone hoses, you'll need them as your normal hoses wont know what to do with the extra air pressure. There are load of companies that will remap your car, but vw specialist are the one to visit (eg awsome gti etc).

Ok, to be honest, you might want to stop there, because now you should have over 170bhp and more torque than your tyres can handle as well as giving you about just under 40 - 50 mpg.

If you want to get more, id do all of the following at the same time as your remap:
larger intercooler
larger turbo / hybrid turbo
polished inlet and head
exhaust / manifold (i personally wouldt go to mad on the exhaust at all, not when your revs finish at 5000)
with all of that done. you should be easily getting 200 - 250 bhp, which is ample for a golf with no LSD, for under a grand you can get a LSD (Limited Slip Differential) fitted which will help to stop your front wheels spinning with all the power and make your car handle better on most roads.

I dont think you'll need much more power after that...!

[CIARA_GTTDI]

excellent lad! thanks..

The rac thingy we got with the car also mentioned it needs the breaks checked, later she did the mot, the mechanic said aw sure they are ok, it'll pass, 1 yr layer the breaks are rubbing / squeeking, he charged me for the pads!! saying its down to wear! anything to make a buck, but no i'd rather he did the intercooler for free, waste his time etc!

I will look into the mods!