1.9 TDI PD smoking: Causes and solutions

Hi forum members,

I'm at my wit's end with my old car... It's a Golf 4 PD with 130 horsepower and 200,000 km on the clock.

He's directing the oil directly from the pump to the exhaust side of the turbo... This causes some oil to accumulate in the downpipe, which results in excessive smoke. For me, this is an indication of excessive crankcase pressure. I initially replaced the valve cover with the membrane.

The problem is, I've replaced EVERYTHING on the engine, and it's still leaking oil from the exhaust side.
I switched.
- 3 valve covers (1 new, 2 used)
- 2 turbochargers (1 refurbished and 1 used), including inlet and outlet pipes.
- Tandem pump
- PD elements
- even the entire engine! (My friend had a used one lying around).

PD values are excellent... All are around +/- 0.0...

And he keeps pushing the oil into the hose... The loader always looks like that after a short time.

And the oil isn't coming from the inside of the engine! The exhaust manifold and cylinder head exhaust ports are completely dry...

Compression measured?

Pressure test?

Compression: 22 bar or higher for both the old and new engines.

No pressure loss, and no abnormalities detected.

So, both of them are feeling pretty down.

Well, isn't it only critical starting from 20 bar...? And if the cylinder was completely worn out, I wouldn't have such good performance values.

It's possible that the cause of the oil consumption lies there.

Speculation: The oil drain line from the turbocharger to the oil pan is clogged. As a test, try blowing through the new line.

If the crankcase pressure were too high, the oil filler cap would fly off. If it's left open, will it stay on top of the opening while the engine is running?
Hopping around is okay.

Hello,

Somewhat far-fetched, but possible.
The engine is "new," and so is the turbo. There's no oil in the exhaust manifold, so it's not coming from the engine.
Suspected cause: A leak in the intercooler system is causing the turbocharger to overspin significantly, which is forcing oil out.
Or, purchased spare parts from questionable sources.
Oil pressure measurement could also be informative. Does the inlet line come directly from the oil filter housing? Could it be the wrong filter or a faulty pressure relief valve?

Sure, here's the translation:

"Vg" translates to "Very Good" in English.
Thilo.