1.9 TDI AVF: Excessive Smoke, No Power

Hello everyone, I need your help again.
"This weekend, I replaced the engine in my Passat, including a new turbocharger. The engine runs very well and smoothly, but it's producing a lot of black smoke, even when idling."
If I increase the engine speed, for example, to 1700 RPM, the excessive soot becomes less visible. I have the feeling, or rather, I believe that the engine is simply not getting enough air.

During a short test drive, he also experienced significant problems building up the turbocharger pressure.
According to the specifications, it doesn't reach 1 bar of line pressure until approximately 2200 RPM. Also, its performance was very weak.

I'm going to check the system now; there might be something wrong with it.

Does anyone perhaps have another idea what it could be?

Thank you very much.

Best regards,
Alex.

alex2479 wrote:

I have the feeling, or rather, I believe that something is simply blocking the airflow.

Did someone forget to remove a piece of cloth or something similar from the airways?
Does it open the storage compartment door?
Does it include the AGR?

Hello Ulf,
So, the intake and pressure paths are clear.
The AGR is closed.

I initially suspected that the VTG (Variable Transmission Gear) was not being controlled correctly.
Since it builds up pressure at higher speeds, and that pressure increases relatively quickly, I assume it works.

Does the turbocharger already provide enough airflow at idle or around 1700 RPM that it would be noticeable if there were a leak in the system?
"Definitely yes under load, but what about when the vehicle is stationary? Because, as I said, even with a slight increase in RPM, the vehicle produces a lot of smoke."

Best regards,
Alex.

Cracked turbocharger boost hoses are a more common issue in the 3B engine. Pay particular attention to the bends in the hoses.

If the engine is making a rough sound when idling, there's likely another problem, such as a stuck throttle valve, a constantly malfunctioning EGR valve, or foreign objects in the intake system.
"Someone may have tampered with the vacuum system, possibly by swapping vacuum hoses."

Best regards, Rainer.

alex2479 wrote:

Does the turbocharger, when idling or at approximately 1700 RPM, already provide so much air that it would be noticeable if there was a leak in the system?

For a stationary vehicle: no.

Please provide us with idle log data.
Fuel injection volume, air mass, basic settings for engine control unit (ECU) group 3, synchronization angle (ECU group 4). Quantity compensation (logging data from ECU groups 1 and 13 simultaneously).

Is the built-in engine in good condition? Are the PD elements, camshaft, and related components okay?
Im LL kannst du den Ladedruckschlauch abnehmen, er darf trotzdem nicht rußen. Sure, I'll do it.
If the air filter box is already heavily sooty, it's either because the air intake is blocked or there's something wrong with the mechanics. Or perhaps the wrong parts were installed. I'm not entirely sure if that's possible with an AVF engine.

Hello,
First of all, thank you for the advice.
I think the problem is solved, but I'll start from the beginning.

We only managed to get the engine running very late last night (it had stopped working due to oil dilution after only 18,000 km).
After starting, it became apparent that the engine was producing a lot of smoke. In the dark, it was difficult to tell whether it was soot or oil.
After a short test drive (700 meters), it also became clear that it wasn't pulling properly.

My initial suspicion was a lack of oxygen.
I reviewed everything again today, but I couldn't find anything. After the engine had been running for 5 minutes, it reported a drop in oil pressure.
In short, approximately 3.5 liters of oil were lost after a total runtime of 20 minutes. So, it was clear that it wasn't soot, but oil. This was also confirmed after I removed the catalytic converter.
It was full of oil. At first, I suspected the crankshaft position sensor, but that was okay. The cause turned out to be the turbocharger.
Get all the oil out of the skin. We need to figure out why this is happening.

Thank you to everyone, nonetheless.

Best regards,
Alex.