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Thread: Exhaust smell, down on power...

  1. #1
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    1.8T AGU Stage 2 down on power: Exhaust smell, 15psi max at WOT

    SOLVED:

    Hey guys, I've reached another milestone problem.

    I have two symptoms to work from.

    Exhaust smell when driving, also I am down on power at wide open throttle, the car is not reaching maximum boost. The higher the gear the more noticeable the power loss.

    I have boost leak tested the car and there is a faint hiss coming from somewhere, But doesn't seem to be a hose.

    TLDR UPDATE:

    • Hiss was identified as leaking injector seals and injector cups via boost leak test with soapy water. Replaced with aluminium injector cups and slightly bigger o-rings. This did not solve lack of power.
    • Brand new set of Bosch injectors. Fuel rate must have been limited. See final post.
    • Tightening of waste gate with helper springs holds power, not sure if essential. 6psi cracking.


    Read the thread for the full journey...
    Last edited by Sirocco20348; 05-08-2019 at 08:51 AM.

  2. #2
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    I did some vagcom testing last night.

    Firstly no errors in engine module.

    However, I logged banks 002, 007, 008 during some 3rd gear wot runs to 7000rpm.

    Valve duty was consistently 99.5%, which indicates a boost leak somewhere in the system.

    Super frustrating, I'll be keenly interested to see where this mongrel leak is, it's not obvious.

  3. #3
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    I might go log these blocks on mine.
    Good luck searching, boost leaks are such a pain.

  4. #4
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    Quote Originally Posted by jmcc View Post
    I might go log these blocks on mine.
    Good luck searching, boost leaks are such a pain.
    I'll post up my results so you know what your looking for tonight.

  5. #5
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    Linked is my logs...

    https://1drv.ms/x/s!ArCKuFTQ_s3egZ0Yl261TOHF9VXbog

    Group 002 has my idle speed... colour coded for ease of viewing.

    Group 007 has the valve duty... always 99.5% throughout the rev range.

    Anyone else notice anything interesting?

  6. #6
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    Update: I had my car smoke tested for misc leaks. One was detected/fixed and improved performance. But unfortunately my car still cannot reach requested boost and my car still stinks of fumes...

    Has anyone had the 3 turbo bolts come loose?

    I am reading a thread where they come loose all the time for various people, especially when modded parts are introduced and vibrations are increased.

    This thread!! :

    VWVortex.com - TURBO TO MANI Bolts coming loose??

    When I put my hand down next to that gasket when cold I totally feel like there is air escaping from that gasket, but it's such a pain in the ass to tighten those bolts. I will have to remove the charge pipe...

    Please anyone chime in with their 5c worth.
    Last edited by Sirocco20348; 19-05-2018 at 10:18 PM.

  7. #7
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    Yeah, totally plausible.

    You'd have to at least replace the gasket and bolts. Given the age, they'd probably break if you re-torqued them, and the gasket has probably blown out anyway.

    As for a solution, high-temp Loctite seems like it'll do the job.
    '07 Transporter 1.9 TDI
    '01 Beetle 2.0

  8. #8
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    Quote Originally Posted by Umai Naa!! View Post
    Yeah, totally plausible.

    You'd have to at least replace the gasket and bolts. Given the age, they'd probably break if you re-torqued them, and the gasket has probably blown out anyway.

    As for a solution, high-temp Loctite seems like it'll do the job.
    Well the turbo was a new install about 45,000km ago with all new hardware. Do you think I could give tightening a go?

    As for thread locker, which one is appropriate for turbos?

    Maybe I should just buy one of those fancy ninja stars/ turbo locking flange if needed

    034Motorsport - 034-R01-8005 - K03/K04 Turbo Locking Flange - priced each

  9. #9
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    I don't think there's any version of loctite that will work on an exhaust manifold, even ultra high temp is only like 350c.
    You could use lockwire or locking bolts they're a pain though. I don't get how the ninja star works, seems like it'd just be a fancy washer. That bolt closest to the block is the worst to get to even under the best circumstances.

  10. #10
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    Look into tab washers.

    You bend one tab over the hex of the fastner, and the other over the edge of the flange.
    '07 Transporter 1.9 TDI
    '01 Beetle 2.0

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