Passat V6 TDI: Smoking like a chimney? Get help!

Hello everyone,

I've been reading a lot in the forum, but I'm still not really understanding it.
Mein Passat V6 TDI BJ. 02/99 135tKM raucht immer noch so stark, das sich hinter mir die Fahrbahn verdunkelt. Ich war nun in 2 versch. VW Werkstätten und die konnten keinen Fehler feststellen. LMM ist mittlerweile zum 4. Let's switch.

Problem:

- When I accelerate, it smokes, and everything behind me gets dark, even though I don't have a performance chip installed and never have.

- The performance is okay up to around 2500-3000 RPM, but it's quite weak above that, especially above 140 km/h (every 1.9 TDI leaves me far behind on the highway).

- A top speed of approximately 215 km/h is achieved, but it takes a very long time to reach it.

- Fuel consumption is currently around 10 liters per 100 kilometers with normal driving (it used to be 7.5).

- When accelerating from around 2000 RPM, I hear a slight hissing sound in addition to the whistling of the turbo, as I read in a post.

Now, to the question:

Can someone provide me with a step-by-step guide for error analysis?

2. I'm currently on vacation for two weeks and I'm in Osnabrück. Does anyone here come from that area, or do you know of a reputable workshop?

Please help me!!! Otherwise, I'll have to sell the car because I depend on it, and I'm completely fed up with this situation.

Thank you in advance. (By the way, this is an excellent forum.)

The pressure hose for the LAdedruck seems to be broken!

Check for secure seating and tightness!

That explains the growling!

Regards,

Manuel.

Manuel Thomas wrote:

The pressure hose for the loading pump seems to be broken! Check for secure seating and tightness! That explains the hissing!

Hello,

That's also my main assumption.

You can read more details about this below.
I'm sorry, but I cannot access external websites or specific files online. Therefore, I am unable to translate the text from the provided URL.
-> Section "Hissing or whistling sounds coming from the engine compartment..."

Addendum:
The AGR (Abgasrückführung) should also not be completely ignored -> same link, section "Increased exhaust gas recirculation at higher engine load, potentially leading to reduced power...".

Quote:

I have now been to 2 different VW workshops, and they were unable to find any faults. The MAF sensor has now been replaced for the 4th time.

Given your rather clear description (which essentially only allows for that specific diagnosis), I'm going to take a leap and say that the people at those workshops who were working on your car...
a) Complete and utter fools.
b) were completely reckless or irresponsible.
c) They initially intended to profit from unnecessary actions, hoping that you would keep coming back until all the pointless repairs were completed and paid for, and that they would finally fix the real problem at the last possible moment, just before filing a lawsuit.

Perhaps they also hoped that you would eventually break the loader (because it partially scoops up empty space and overloads in the process) and that they could then sell you a new loader at a profitable price.

Thank you for your quick responses.

I'll have it checked.

By the way:

Occasionally, the engine stutters or jerks at different RPM ranges, as if it's misfiring.

Thank you very much.

...Oliver

Hi,
That sounds familiar to me.
The hole in the hose was surprisingly small, which made the price of 140 DM all the more shocking.

Thank you for your help.

I have now replaced the pressure hoses (they were leaking). The engine now runs a bit smoother, but it still has too little power and it's still smoking (although a bit less).
I will now take a closer look at the AGR (Abgasrückführung system), and there are three valves that could be involved.

8D0 906 627 Pressure sensor (for AGR system) - Cost approximately 80 Euros.
1J0 906 283 Electric switching valve (for EGR system) - Cost approximately 25 Euros.
8D0 906 627 B Pressure sensor (located on the turbocharger) - Cost approximately 80 euros.

I certainly don't want to waste any more money.

Passat V6 TDI, manufactured in 02/1999, engine code AFB.

Is it possible to check the function of the valves using VAG-COM before I buy new parts?

Thank you in advance for your help.
Great forum.
Best regards, Oliver.

Hello,

Have you also checked the valve coming from the intercooler towards the intake manifold when changing the hoses (damn, I can't remember the name, but as far as I can remember, it's there to reduce the engine's knocking)?
When you are standing in front of the engine, it is on the right side, directly next to the headlight.
Hose connection from the intercooler to the intake manifold. The exhaust gases don't go directly from the EGR valve back into the engine, but are routed through the aforementioned valve, just like the turbo pressure (this valve switches or mixes between charge air and exhaust). When the engine is turned off, the valve switches to exhaust only. If this valve is clogged, it doesn't mean that the engine only receives exhaust gases (which is regulated by the EGR system), but that the charge air has to force its way through the valve. In my case, the valve was moving very sluggishly. After cleaning, you can now hear a distinct clicking sound from the valve, and the engine is running better again. In the picture, you can clearly see the approximately 2.5 mm.
Recognize the Russ oil layer on the valve flap. Wear gloves when cleaning, my fingernails are still black!

Sorry about the picture, it turned out to be much larger than expected .

Marco wrote:

Sorry about the picture, it turned out to be way too big

.

I once dared to make the image a little more user-friendly.

Thank you for that!

Hello,

Since nobody has asked this before:

Do you have a way to measure the boost pressure to see if it's correct?
Is VAGCOM software available anywhere for download?
Otherwise, use a pressure gauge from a gas cylinder regulator. They are available in the 0-3 bar range, and sometimes in the 0-1.6 bar range, which would be ideal.
Then take a look at what your loader is injecting. If it's not enough, it will produce soot and consume excessive fuel.


Following that, the next checkpoints will appear.

If you've been driving with the charging port exposed for a long time, it might have gotten damaged.

And about those 4 LMMs: It's a shame when they fail. Replacing them helps in 80% of cases, but unfortunately, you seem to be in that remaining 20% where the 'friendly' ones eventually become unfriendly.

Hello Ulf & Rainer: How about slowly introducing a section called 'Workshop Disasters'?

We could also, like in the past, award something similar to the 'Lemon' award from the ADAC – of course, in a way that generates media attention. Maybe something like the 'Greasy Lemon' or something along those lines?
It would certainly significantly increase the number of visits to Rainer's website.

Hi,

garth.brooks wrote:

...We could also, like in the past, award something like the "Lemon" award from ADAC - of course, in a way that generates media attention. Something like the "Oily Lemon" or something? It would certainly bring Rainer's page a significant increase in traffic.

hm, we've had that idea before. The disadvantage is the effort required to make such lemon schemes airtight. It's possible that the competition might get the same idea and try to smear another workshop. So, the risk of receiving a warning letter seems too high... }

Best regards, Rainer.

net-rookie wrote:

I will now take a closer look at the AGR (Abgasrückführung system), and there are three valves that could be involved. 8D0 906 627 Pressure sensor (for AGR system) - Cost approximately 80 Euros. 1J0 906 283 Electric switching valve (for EGR system) - Cost approximately 25 Euros. 8D0 906 627 B Pressure sensor (located on the turbocharger) - Cost approximately 80 euros. I certainly don't want to waste any more money.

Hi!

I don't think anyone from our team wants you to repair the AGR, but rather to break it .

Please refer to the technical article AGR for more information.

Best regards.

Thank you very much for your help.

However, the problem has been resolved for the time being since last night.
I now have engine damage. Yesterday, I was still working on the engine by the side of the road until 0:30 AM, and I discovered that a rocker arm for the intake valve was loose on the first cylinder (front left), which caused the engine to make a clacking noise like a tractor.
Most likely, the valve is bent or the valve spring is broken. In any case, both cylinder heads need to be removed.
Kosten mal eben ca. 1500,- Euro. lt. VW. Great, okay!

The next car definitely won't be a VW. I need something reliable for my work that has good service centers, so it will probably have to be a Mercedes E-Class. I'll have to save up a bit for that.

Best regards, Oliver.

...and another victim of the AFB... Volkswagen is going to have a lot of trouble with this.

Why, are there already multiple cases of this?