Hi all,

 

 

Many thanks for making me feel so welcome. This is my first post, but I am posting on behalf on the owner of the car, who doesn't use computers.

 

The car is a 11/2005 Octavia II estate, 1.9 TDI DSG, with the BKC engine and without a DPF. It has done 181000 reliable miles, and has full service history. The last service was at 172000 miles (all filters, oil, etc).

 

Last week, injector 1 has been renewed and the EGR valve and various pipes had carbon scraped out and parts washed. The car was running briliantly, sounded crisp and clean and drove considerably better.

 

Coming down a hill, the car suddenly -boompf- came to a halt and wouldn't restart.

 

Checks and faults read:

ECU is communicating

Crank shaft sensor is working

Oxygen sensor is working

In tank fuel pump is drawing 3A and pumps fuel

injectors we knew are working

 

When the pipe from the intercooler pipe to the EGR valve off, a lot of smoke came out, suggesting unburnt fuel. The engine immediately starts, but after a while smoke comes out of the air box intake and actually, when we took the oil filler cap off, it smokes like a whale.

 

We took the air filter out and it is still relatively clean) changed 10 000 miles ago, and we cannot see anything like a plastic bag or so blocking the air intake. Then, we disconnected the right hand intercooler pipe from the bottom, to see whether there was any blockage in the intercooler. It wasn't filled with oil or debris in it and didn't make a difference.

 

We suspected the vanes of the turbo either collapsing, or being stuck. But from experience, this actually rarely happens. Someone suggested worn rings,but I am actually not too sure. We will investigate further but could anyone have a suggestion?

 

Many thanks in advance. Its been a brilliantly reliable workhorse, and we hope to use it for a good few miles more.

 

 

Cheers,

 

 

Bert 

Does it start if you disconnect the boost pipe from the intercooler?

Thanks for your response: sorry, but, an intercooler doesn't have a boost pipe, to my knowledge?  What pipe do you mean, and where do you disconnect it? 

 

I have found a quick picture from a BLS engine: could you kindly indicate what number?

 

 

Many thanks!

 

Bert

The boost pipe goes from the turbo to the intercooler then to the air intake.

Hi Softscoop,

 

It would actually be helpful if I posted the correct BKC engine with intercooler up, isn't it.

 

Right:

 

 

If we disconnect the pipe at point 2: it starts. Put it back on, it dies within seconds.

 

Hope this helps!

 

Bert

When the pipe is reconnected does it dump the air back out through the air filter then stall?

Thanks for your response.

 

Thats correct: we see the exhaust gases coming out through the front air intake. Also, when holding your hand over the exhaust, we don't feel anything, hence our thought that the cat might have collapsed. 

 

But disconnecting that didn't make a difference.

 

Cheers,

 

Bert

Oh, and also, when we disconnect the pipe at point 2, and press the accelerator, very little air comes through.

 

HTH,

 

Bert

Have you checked the wastegate in the turbo for blockage?

Edited 26 March, 201610 yr by King85

Good idea: we'll be on the case.

Cheers,

Bert

Okay: it transpires that the impeller of the turbo has disintegrated, it is full of debris blocking it up, and there is oil all around the pipe work coming off the turbo.

There we are then: a result!

Thanks again for your suggestions.... Now onto the case of fixing, refurbishing, or overhauling!

Cheers,

Bert

At least you now know so you can get it sorted!