More smoke than expected

[Marzocchi]

Hi all, my current projekt:
1.9l VP37 ALH engine
11mm pump
Bosio Race 520 0.260 nozzles
GTD1756VRK Turbo
Darkside SMIC

Boost is 2bar/29PSI. Power goal: 200hp without smoke.
The tune was done remotely by a well known diesel expert that does several TDI tunes a week in all different configurations.

Just now I have the following problem:
The engine most likely has the desired power. Unfortunately there is quite a lot of smoke, althogh 200hp should be possible smoke free with 29psi.
We've now reduced fuel until almost smoke free, but now it by far doesn't reach 200hp. Maybe approx 160hp.

I've double checked the timing. Nozzles are calibrated.

Do you have any ideas what the problem might be and how to solve it? Thanks!

 

[BustedBolts]

Have logs been taken? If nozzles where calibrated, where they done properly or just pop test and assumed good? And is the smoke still there at full boost or just spool up?

 

[Marzocchi]

I cleaned the injectors carefully and pop tested them with cheap pop tester. Spray pattern, sound and pressure for 1st stage (220bar) looked ok.
Unfortunately I don't have equipment for 2nd stage test.
Smoke is still there at full boost.
I can do VCDS logs. What makes sense to tog? Tuner removed MAF.

 

[J_dude]

Legend has it @burpod is your man for these sort of things.

 

[Marzocchi]

Legend has it @burpod is your man for these sort of things.

Thanks, mabye burpod has an idea

 

[tdi_my live]

How much Air you have at 29psi?
Diesel need Air not pressure.

 

[Marzocchi]

How do I know?

 

[tdi_my live]

The 1000 mg Air limiter is reased Up?

 

[Marzocchi]

Unfortunately I'm not too familiar with the maps and details. May I send you the file?

 

[tdi_my live]

You have PM with my email

 

[NewTdi]

Legend has it @burpod is your man for these sort of things.

Yes, Burpod does!

 

[ecala001]

@burpod is the man!

I have similar setup except I have .230 and a gtd1756vrk. He got my setup smoke-free even at WOT!

 

[Marzocchi]

Thanks for you help guys.
@tdi_my live was able to fix my problem with awesome knowledge and experience.
His friendly support is outstanding.