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R5 smoking hard srating uphill

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Discussion starter · #21 ·
treg limp

Hi pikannin
Vane arm moves when going to idle as you describe, i have swopped out the boost sensor from my v6 no change, swopped the actuator valve with egr one, no change, egr is blanked off. Can it be the dpf it shows 1700mbar and should be 2200mbar when it throws the limp mode.
Nico
 
#22 ·
i'm not familiar with DPF systems. sorry :(
 
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#23 ·
Heavy smoke exhaust plume and too high oil level (fuel in oil) are really DPF problem symptoms. Others: loss in engine power, inceased fuel consumption, unstable idle revs, engine unusual sound pattern (hissing), DPF icon on MFD.
 
#25 ·
nober said:
Got Vag working and logged turbo boost seems low accross range. Any comments on the fuelling and boost log.
Click to expand...
Start checking for hoses cracked and or leaking on the turbo compressor side to and from the intercooler. Also check for cracks or leaks on the inlet to the turbo, from the Aircleaner to the MAF to the turbo charger.

You have to inspect very, very carefully, leaks can be hard to pin point, or in hard to see areas. Pull every hose, and inspect, then reinstall.

Also check for damage or puncture to your intercooler, with a leakdown test.

If all of those are good, maybe time to test the turbocharger for wear and or replacement.

Smoke indicates you are getting enough fuel, but not getting enough air in there to burn all the fuel. The air is either leaking out, or not enough boost is being made to burn all the fuel.

Put all those logs on a graph, with requested boost and actual, on VAG-COM VCDS and then take a screen shot, put it in Microsoft paint with "Control V" to paste it or whatever, and then "save" it. Then host the graph on a picture hosting service for free, like Photo bucket. Then link the pic on photobucket to here on Club Touareg.
 
Discussion starter · #26 ·
Limping

HI Guys
Got the van back from VW agents, most expensive carwash to date, R1600 and no clue as to fault. Their best effort was to tell me to put the egr back. Now considering removing the cat , does anyone know if these block up, mine is the model before dpf. Only fault it gives on VAG is low boost pressure, no other faults. If I connect the vacuum line direct it does not go into limp, but I am concerned about possible overboost.
 
#27 ·
check that your turbo actuator behaves like mine.


Your vacuum actuator for the turbo (sits on the turbo - round silver thing) may be faulty. Or you may have a leak in the vacuum pipe or the solenoid is dud.

Check the routing of the vacuum pipes as well.

Image
 

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#28 ·
Other than that I suspect you have a boost leak or a blocked exhaust.

You mention you have a pre-dpf R5 but you also mention that you read DPF values via vagcom ???

If you have DPF then go see a tuner to take the DPF out and recode the ecu to ignore the DPF.

If you have a pre-DPF R5, take the exhaust off, and use a sharpened rod to gouge out the inside of the CAT and put the exhaust back.
 
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Discussion starter · #29 ·
Hi Guys
I have a pre DPF 2005. I have run the N75 test and the turbo learning procedure 11 on the options in VAG. The actuator moves freely and full movement. Therefore I believe the vacuum is ok. There are no leaks on the boost side. Does the cat tend to clog, I have no issues to gut it.
 
#30 ·
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Discussion starter · #32 ·
limping

Hi Guys
The fun continues, de cat this morning, runs a bit better but still limp mode on underboost. Slow on pickup, adjusted stop screw and boost picked up see attached logs. 1was after de cat, 2 N75 excluded 3 after stop adjustment, 4 with N75 excluded. Looks like the turbo needs to go back to rebuilder. Vacuum around 20 inch Hg. Tandem pump leaking into head. Has anyone replaced the tandem pump with electrcal vacuum and diesel pumps?
:mad:
 

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#34 ·
nober said:
Hi Guys
Does anyone have an exploded view of the tandem pump, i need to see if it feeds direct into the head or via a pipe. Also info on testing fuel pressure.
Nico
Click to expand...
Via a pipe. The pump is the vacuum pump and diesel pump (hence tandem pump)

If the pump's seals fail you get diesel in the oil. I don't know of a rebuild kit. Just a gasket kit between the pump and head

Image


Image
 
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#36 ·
nober said:
Thanks Pikanini
Do you know which of the connections on the pic is the feed line to the injectors.
Nico
Click to expand...
AFAIK they can only go on one way.

Follow the pipes. The routing is as follows.

There is a two pipes coming along the firewall. One is the feed to the filter. From the filter there is a pipe that feeds the tandem pump. From the tandem pipe there is a pipe that feeds the inside pipe along the engine to the injectors. Then the outside pipe returns the fuel to the filter (this line has the fuel temp sensor on it) and then from the filter the fuel heat exchanger and then from the exchanger back to the fuel tank along the firewall.

See attached files

I can take pics of mine if necessary.
 

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#37 ·
PS : Where in SA are you? I am in PTA this week.
 
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#40 ·
nober said:
Hi was just concerned as other pumps go into head,I will be putting in the electrical pump this week. I am in Kempton close to airport.
Thanks
Nico
Click to expand...
Electrical pump?

The tandem pump feeds diesel to the injectors at well over 3.5 bar @ 1500rpm.

I doubt an electrical pump will achieve that. You will get air bubbles in the lines and cavitation in the injectors.

If your tandem pump isn't working properly, spend the money and buy a new one. I got mine imported from seekpart24 for half the dealer price and had it within 3 days.
 
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nober
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