Club 80-90 Forums

Looks like I'm not going to make it Am stuck here and this is completely wrecking my head know this is not the technical forum but any help appreciated from the diesel contingent am running an aaz with a KKK14 turbo was working fine till i fitted a chargecooler which leaked so have stripped it all out and back to a jx inlet manifold with the BOV taken out and blocked by a bung all surfaces gasketted properly and sealed hoses in good condition am now using the jx short inlet hose. Engine boosts up to 3/4 bar max but normally only runs around 1/2bar boost but keeps losing boost around 1/2 bar of boost pressure usually around 3000 rpm any ideas guys going to change the turbo now still might make it fingers x'd

wastegate opening to soon then sticking????

Fuel supply not dropping off and thus not generating combustion to drive the turbo... or something similarly odd??

just screwded the actuator rod for the wastegate right in and boosts a bit more but same as before fuel supply not been touched and runs well when not losing boost then black smoke when boost is lost At this point there is no way am making it or your cabinet lyoddie sorry have a great weekend guys

Paul, are you sure you don't have a leak in the pipe beteen turbo and inlet manifold?

Paul, just remembered something that happened to me that produced similar results.

Have the snorkel out of the rear quarter, make sure the oval pipe isn't collapsing. When mine started going it made the van loose all power and smoke black smoke.

Took me a little while to track it down, but was obvious as soon as i had that pipe out. Maybe try disconnecting the inlet from the snorkel pipe and give it a quick run with it sucking air straight in from the engine bay?

Is it at all possible that one of your other pipes has no splits or tears but could be collapsing under vacuum?

jebiga41 wrote:just screwded the actuator rod for the wastegate right in and boosts a bit more but same as before fuel supply not been touched and runs well when not losing boost then black smoke when boost is lost At this point there is no way am making it or your cabinet lyoddie sorry have a great weekend guys

Hope you get it sorted (not just to get my unit)
Fingers crossed one of the above answers gets you going

1. What Al said

2. Just check your air filter

We have been speaking on the phone a few times about this today. It sounds as though the boosted air is blowing out of somewhere at 3/4 bar. Where can it go? Faulty rubber pipe from the turbo outlet to manifold or possibly back through a seal in the turbo itself. It sounds as though something gives even before the wastegate pops off. I know that the rubber pipe to the inlet manifold can go porous if oil has lodged there. Bummer.

If you do decide you want to do the trip, my Syncro is sitting here doing nothing and you can borrow that. I got relies over from Oz this weekend so it wont be used

Thanks for offer Andrew but going to have to give it a miss and not sure if I trust you gearbox, might cook on the way
Will have a look at the whole snorkel set up tomorrow, even cleaned the K&N the night before but will try it without it just to see

syncrodoug wrote:Paul, are you sure you don't have a leak in the pipe beteen turbo and inlet manifold?

Am seriuosly thinking that may have a pinhole leak somewhere that I can't find whih may have come up with refitting the hose or porosity but have even tried three jx inlet pipes I have knocking around unless all three are damaged ? changed the turbo and also blocked off that wastegate runs at max 1/2 bar and from what i could see black smoking but will have a look again in the morning as was dark will replace the boost pipes to the pump tomorrow and not t in the boost guage to see if thats leaking just a matter of working through it again and fitting new hoses Thanks for all the help and suggestions guys really appreciate demonstrates when it comes down to it its what this forum is all about enjoy your weekend

The hose from the turbo outlet to the inlet manifold is NLA from VW since 01/08/2010 but is available from Classic Parts in Germany for €80

Had a no boost black smoke experience coming back from Cornwall a few years back that niceley recoloured the boat i was towing!

That was down to a tear in one of the boost pipes right beside the jubilee clip.

just re-examined all the pipes I have they all seem to have tears from 20 years of jubilee clips in them have put sealant on the outside of one and them wrapped it in silicone tape and hooked it up hopefully will hold will see in the morning. but looks like need a new hose mr baxter has them £31.97 (inc. VAT)
http://www.brickwerks.co.uk/shop?page=s ... ory_id=111" onclick="window.open(this.href);return false;

jebiga41 wrote: mr baxter has them £31.97 (inc. VAT)

Order me up one as well Paul ..... might as well

...but looks like need a new hose mr baxter has them £31.97 (inc. VAT)
http://www.brickwerks.co.uk/shop?page=s" onclick="window.open(this.href);return false; ... ory_id=111

They look like SFS high quality silicone jobbies

Finally did all my intercooler with thems, top quality, no probs since then:-

The best clips to use are Murray clamps: Not sure if SimonB does them too, but def the business (aircraft style). They won't damage your hoses..

http://www.sfsperformance.co.uk/hose_clamps.asp#murray

HarryMann wrote: The best clips to use are Murray clamps: Not sure if SimonB does them too, but def the business (aircraft style). They won't damage your hoses..

These clamps are brilliant ..... but very expensive

http://www.oetiker.com/content.asp?l=4&idNavig=88" onclick="window.open(this.href);return false;