Golf 3 TDI 110 HP + Chip + Large Intercooler +1 30 HP PD Turbo

Hello everyone!

Okay, here's a short story about my car, or rather, its modifications.

Originally, I had the 110 horsepower TDI AFN engine installed. Last year, I had a chip installed (performance is now approximately 140 horsepower).
However, last winter I started two projects that I actually finished today. Firstly, it has a larger radiator (at the front), and secondly, it features the turbocharger from a 130 hp common-rail Golf 4.
Today, I drove it for the first time, covering a few meters. However, I noticed that the turbo started to emit a little smoke after a short period of acceleration in first and second gear. Okay, here's my question for you!
What could be the reason for that? Could it perhaps be due to the chip's settings? It seems this needs to be replaced, as it was installed under the original conditions (without significant additional equipment and a 130 HP turbo).

I would really appreciate your help!

Hi,

Quote:

Now, I had to notice that the turbo (after a short acceleration in 1st and 2nd gear) started to emit a little smoke. Now, here's my question for you! What could be the reason for that!

if the proper drainage of the lubricating oil from the loader is ensured, then blue smoke (correct?) was probably the reason the previous owner sold the loader .
That's why I only sell new parts in my shop, and not any old junk from auction houses.

If it's black smoke: The boost pressure with a new turbocharger is almost the same as with the old one, because it's set in the engine control unit (ECU) software. Therefore, no significant performance degradation should be expected in the regulated state.
Furthermore, it's possible that the control system for the new turbocharger is not compatible with the software, and that the software may have been overly lenient in its handling of soot emissions (resulting in black smoke during the turbocharger's initial adjustment phase and/or during rapid load/speed changes).

Best regards, Rainer.

Hi!

Okay, it's actually a light (white), thin smoke. It also smells a bit strange. But the weird thing is that it runs perfectly fine when idling, and for a long time. Only when I really put it under stress does it smoke, but as I said, not much.

Well, light and white could indicate a lot of burnt oil: in this case, the loader seals might be failing (which would be a reason for the previous owner to dispose of it), or, as I said, the oil might not be returning properly to the oil pan (check the flexible hose/fitting).
If the used loader is from eBay, what do you expect the reason is for someone selling a used loader? Probably not, because the new one shines more beautifully, right?

Best regards, Rainer.

Okay! I'll look into that.
Thank you in advance for your help!
I'll post in the next few days to let you know if anything has changed, or not .

If the used loader is from eBay: what do you expect, and why would someone sell a used loader? Probably not, because the new one shines more beautifully, right?


What's particularly nice is how the loader looks even in the photo. If a used loader has new protective caps on the fresh air housing and oil connections, the seller probably needed a replacement loader – and for a reason: the loader being sold is likely not in good condition.

Rainer K. wrote:

What do you expect is the reason someone would sell a used loader? Certainly not, because the new one shines more beautifully, right?

The only acceptable reasons would be:
the conversion to a different (larger tuning-) turbocharger.
Demolition derby of a car involved in an accident with relatively low mileage.
each time without because the old loader broke down.

I would explicitly include something like that in a proposal - and as an interested party, I would elegantly ignore all offers that do not have the corresponding information (i.e., the vast majority ).

So!!!!

I did some more test runs today.
Here's what came out!
The loader isn't smoking anymore! However, I think there's still something off with the tuning or settings. It definitely accelerates well, but I don't think it's 100% accurate.
Here are some more questions I have for you!
I actually made my own stainless steel intercooler system! Now, I still don't know whether I need to reduce the diameter of the pipe where the hose connects, or not! All the pipes up to the turbo connection have a diameter of 60 mm! Could it be possible that I might need to reduce the diameter to 60 mm, say, over the last 30 cm?
On the other hand, I also installed a boost pressure gauge today, but it didn't display anything .
Does anyone happen to be from the Augsburg area who is really knowledgeable about TDIs?

Hello!

Here's a problem I'm having with my car!
A few days ago, the car was actually running really well (with good acceleration), considering that the software hadn't yet been optimized for the new turbo and exhaust system.
But since the day before yesterday, it's been running really badly!
Basically, it doesn't accelerate at all, or rather, you simply don't notice the turbocharger! He accelerates very slowly, and that's the case throughout the entire process.
It's not an air mass flow sensor! I've already tried that!
Now, here's my question for you! Do you guys know what's going on?

P.S.: Could it be that the engine is now running differently because my modifications might be allowing it to take in a slightly larger amount of air?

We need more data here, logs... pressure readings. Speculation is not helpful.

It's a diesel engine... it's not very sensitive to excess air.

So, I'm slowly reaching the end of my 'knowledge' .

I've already tried so many things, but nothing has worked so far.

Sure, please provide the text you would like me to translate from German to English.

I've replaced several (almost all) of the vacuum hoses, tried two mass airflow sensors, and even put the old AFN turbocharger back in (it was 100% functional), and the error memory shows no errors!
But it still doesn't accelerate (not like a diesel with its approximately 150 horsepower).
Currently, even my Golf 3 Variant with a 90 HP TDI engine and a chip is better than my summer car .

Does anyone have any idea what could be broken?!
How about the wastegate valve?

By the way, it seems to me that he's not building up any pressure, or rather, that he's building up too little.

Neno wrote:

Does anyone have any idea what could be broken?!??!

Use VAG-COM, create logs, and we'll be able to help you.

Or:

Describe your errors in more detail, without providing any meaningful measurements, and no one will be able to help you.

It is done!! JJUUHUUUU!!!

Error found!

The boost pressure control valve was 'somehow' leaking! It was only delivering half the pressure it should have. The new parts are already installed, and the car is running like a rocket again!

It is done!! JJUUHUUUU!!!

Error found!

The boost pressure control valve was 'somehow' leaking! It was only delivering half the pressure it should have. The new parts are already installed, and the car is running like a rocket again!

Hi,

Small question: Where is the boost pressure control valve located?


Regards,
'Dj'

dj1 wrote:

Small question: Where is the boost control valve located?

In the GIV, it's on the upper edge of the cylinder head, below the windshield wipers.