please read and help with my leon fr pd150 thanks

[rorz7370]

The problem is at very high revs or when thrashed the car smokes blue smoke for a while after even if idle but then goes away.

History which might help

First bought the car thought it was standard but after some help from fordy and dan fr after reading a boost log found out it was remaped and boosting/spiking to 1.9 (revo stage 1), this was lowered to around 1.7 by fordy but still had a little boost spike because it was hard for him with how revo do the smoke map. Before this i changed the camshaft as that went, it was a forged steel with elring bearings black ina lifters bought from redmans on ebay.. after i had the map sorted i had it mapped again by fordy as i tried a black smoke remap which he edited, a few month after the turbo blew in half in third gear at high revs, before this i noticed will boosting in second gear the car made a loud bang lost all power and returned power after. (I learned this was because to much egts) anyway a replaced the turbo with a re con unit off ebay braided type oil feed from darkside along with a brand new intercooler and all intake cleaned, new sump and a full service new gaskets nuts etc. Ever since this tho the car has smoked at high revs which i thought would be oil burning off from the exhaust from the car dumping its oil in there. Now am thinking is there a problem?

Compression is 420psi on all for cylinders, car does same no matter which map is on it the original black smoke or the one ive bought from fordy his own remap not an edited one which pulls nice and its been logged multi times to get it right so no spikes etc, cam angle is 0.6

Tboughts are valve guides, valve stem seals, or turbo seal but what does my head in is its a re con unit and looked like new..

Thanks for any help its appreciated

 

[rorz7370]

Heres the log file to be downloaded from my drive

https://drive.google.com/file/d/0B2c_XV0a26gURjdEY3Zsb0pBRVE/edit?usp=docslist_api

 

[rorz7370]

Can nobody give advise? Ill add miles 127.000 bump

 

[Muttley]

Since it has a custom remap and you admit to subjecting it to high revs and thrashing, there are a lot of things that could be wrong. Any diesel will smoke if you manage to get the revs high enough, the fuel cannot burn completely in the short time it is in the cylinder.

Do you still have the original catalyst in the exhaust? If so, and it had oil dumped on it from the turbo failure, then it's probably damaged and not able to cope with too much unburned fuel, which is what you get at high revs. If you have removed the catalyst, then there is probably still some oil left in the pipes which may account for the blue smoke as the heat from running at high revs gets to it. How long ago was the turbo replaced?

 

[rorz7370]

It was replaced 6 months ago and ive spoken to who i bought the recon from and they said its mellet parts, its a straight turbo back pipe but a think it does have sport baffles in the box, i think its butning oil from exhaust but its been a while now and its strange its only after going above 4000rpm ish or say over 115mph with full throttle, it smokes on start up but goes away and unless a thrash it the cars fine except a mad weriod engine shake that happens at idle

Thanks for your reply

 

[rorz7370]

Am thinking injector seals valve seals or guides (valves vibrating at high rpm) or turbo seals but it shouldnt be the turbo.. forgot to say the engine shke doesnt happen all the time more on a slanted driveway that happens

 

[rorz7370]

And i understand the black smoke wi remaps and what you say.. its when a stop at traffic lights or pull up after it pours wi blue smoke like a chimney which then gets better and better intill it stops smoking again, this is whats bothering me. Really hope you can point me in the right direction or save me changing parts thats not needed, ive spent 3000 on this doing it up all ready and dont wana sell it, egr is deleted also and it has a dummy cat fitted but should be hollow

 

[rorz7370]

Ano am posting like a gooden but a need an answer to this or at least what people would start with finish with, theres loads of 1.9 tdis with this problem after a turbo has gone but no answers.

Am thinking of getting a second hand head, hopefully get a good one thats not been skimmed or from a damaged head gasket, then fit new valve seals, my forged steel cam/ina lifters new headgasket, injector seals and see what this brings but that will cost me loads and alot of work

 

[Muttley]

I've not seen this kind of problem discussed on this forum before, and it's well outside the normal operating parameters of the engine so it's a bit difficult to guess. As its associated with getting the engine very hot, I'd tend to look at the turbo first, as that will be seeing the most extreme heat excursions.

Oil will only get in from the valve stems if the inlet is sucking air in, which doesn't happen very often with a turbocharged car. If the smoke vanishes once the turbo spins up then I suppose it might be valve stems, only leaking in when the turbo is not adding pressure to the inlet.

 

[rorz7370]

Thanks again muttley for the reply. Theres alot on the internet with 1.9 pds on other sites with this problem un solved if i get this sorted my car will be a beast a say thrash it but ive only done this odd time cos of this problem and when 2.0pds bmws try having a go up my arse am a 1.9 fan all the way lol and love smokeing em but a think am guna out standard map on intill a get it sorted.. is there anyway timing can be out when ive done camshaft? I put a new continental belt febi water pump and litens tensioner all oem and my angle is 0.6 on camshaft so a dont think it can be but thought id ask

 

[Muttley]

If the cam has been set with the proper tools, then it should be spot on. There is a well-defined procedure to go through, using special tools to lock the camshaft and crankshaft and position the tensioner.

I had a bog-standard TDI 150 Sport Toledo II, and it was very nice indeed, I never felt I needed more power and could get out of any motorway situation forwards if I had to (you know, clowns to the left of you, jokers to the right and some twit trying to look in your boot).

 

[rorz7370]

Yea they do go alright ive got it mapped so the boost doesnt stop it goes all way to about 4000 before cutting off and its no much other golfs gt tdis or leons or any 1.9 its these 2.0 bms and and people in 2.0 pds lol so if it wasnt mapped they wud do me, ive done a video earlier of the problem guna save to drive and post it on here see what ya recon, cam was done with lazer vw 1.9 timing lock set ive done loads so a dont think it is timing but a thought id ask

 

[rorz7370]

Its a large file 600mb a needed to make it a clear picture. A warm car up then film it as normal then take it for a drive and thrash and the end to show what happens a paused it while a was driving heres the link...

https://drive.google.com/file/d/0B2c_XV0a26gUZE5YT09nX3JoRDg/edit?usp=docslist_api

 

[Muttley]

Hmmm. That's a fairly light haze, but the tailpipe is heavily sooted up so there is something going on. Can you tell if it's oil, or part-burned fuel - what does it smell of? (This is a shot in the dark mind you)

I'm not sure why you pulled the pipe off the EGR body to show the anti-shudder flap was open? Nothing out of the ordinary in there.

Another shot in the dark, but how much oil is in the engine? If it is at or above the "full" mark on the dipstick then you will splash a lot around during a fast run, which will be sent to the inlet by the PCV valve.

I'm only guessing though - I'm surprised nobody else has come in to add their opinions.

 

[rorz7370]

Its 3 quarts up on the dotted part of dipstick, there is all going in inlet from breather but nothing more than normal id say, a pulled pipe of egr to show were oil builds up, id wiped it away but theres norm a small puddle on the egr ledge. Can pressure build up anywere and cause it to push oil into combustion? Cars been serviced oil wise loads with me doing it when a first got it then cam went then turbo its probley had 5 oil changes in a year and half and i always used approved 505.01.. its doing my head in.. its definitely an oil smell and blue colour a new it would be hard to see on cam but it chokes ya when your there.. a wanted to spend money on new seats alloys etc but theres always sommet.. ano nobody replys as much as they used to on here thanks thou to you for trying

 

[rorz7370]

Could it be map related? Ive just put back on the revo stage 1 which my car came with and took it for a thrash 1st time smoked a little like it did av done it 3 times now and its nowere near as bad the last time it dint really smoke at all

 

[rorz7370]

Ano it sounds stupid because it can be cos of the map but id tried 2x diffrent a black smoke map and a custom, but now ive reverted back to the revo i was told was a bad map check my other thread cars not doing it well as of yet from earlier, car feels slower when turbo kicks in with revo but still way anuff if it means my car will be ok

 

[rorz7370]

Seams to have stopped will post if it comes back and will add rep to you muttley for trying to help thanks..

Ps a should of tried this before but id tries 2 diffrent maps lol

 

[Muttley]

Well, I'm glad it has stopped for now, but I'm still wondering why the map should result in this specific behaviour. Maybe the engine is getting hotter with the more radical maps (it's practically certain that it is) and that particular corner of the map is a little bit rich? So you're getting some unburned fuel (that the catalyst would normally deal with) out of the back.

Or, the more radical maps will have higher boost and this is somehow resulting in more oil in the crankcase vapours? I'm fairly certain that is where the oil you see in the EGR body is coming from. Is there less of that now with the calmer map?

 

[rorz7370]

Ano this is a proper puzzle, there is still a little oil there but not as much ill check in a couple of days to see if it goes the same.. am just confussed with it as the map thats on after i fixed the cam caused well shoul a say an engine shake started so a posted on here to be told the map wasnt the best of maps as revo back then left alot to be desired and just ran maps off stock limits, but am the think of this map was on from the first owner am third and second bought it at 39.000 miles and clutch went which they did under warranty at 40.000 car did 70.000 more miles before i got it so that map really dint kill anything after other maps ive had engine bang lost power for it to come back apparently cos of egts to much hot air in the end the turbo blew up, a then got another map and the graph from the log did look good but it smoked well it always smoked when thrashed at high rpm after new turbo.. a really hope that uts rather sorted it self out or burnt off oil and its ok now a do love the car and want to keep it