2003 My symptoms......My guess = intercooler pipes

[jbleu101]

Entrance ramp to freeway going thru the gears to get up to speed. 3rd gear 4000ish RPM's engine makes a sound best described as Pppfffffffffffshtttttttt then black smoke. Shut engine off and coasted to the side of the road. Could not find any issues, nothing leaking. Restarted - engine sounded fine. Drove home...could hear turbo whine.....excessively loud turbo whine and lots of black smoke ONLY when you gave it too much accelerator. If you kept RPM's low you could drive with no smoke. Turbo sounded like a police siren. Boost was -.5 or -.05 and when driving it was -.07 or -.7 almost the entire time. Water temps were normal. I had scan guage to give me the boost numbers and lots of other numbers if they are necessary. No codes and no "pending codes" per scan guage. I have Vag com, too....unregistered. What else do you need to know? I have a 1.8T pancake pipe....

I could see the pancake pipe was still connected ok. Behind the engine I could see some oil but it did not look like it was new. nor was it everywhere. It was mainly on the black rubber pipe crossing behind the motor on the passenger side about the level of the pancake pipe.

 

[1.9glstdi]

yep probably a boost hose some were.

 

[LNXGUY]

Sounds like you popped a IC hose.

 

[TDI-JAY]

This happened to me last week coming down the highway, downshifted to pass some idiot going to slow - put my foot into it and PSSSSSSSSHT (Boost gauge goes from 26 PSI to ZERO). Tail between my legs I get off the highway, thanksfully was the upper IC pipe where it goes into the 90 degree before the intake manifold. Quick adustment & I was back in action!

 

[jbleu101]

Sweet. Glad I was able to keep the temps low enough to not cause turbo problems. I assume that is waht could happen if I kept driving my normal 80mph. I will look at the intake manifold tomorrow. Do I need to remove the fender liner at this point or just take a look around from intake to intercooler? Going to do some more research now. THanks for all the quick help.

 

[LNXGUY]

Sweet. Glad I was able to keep the temps low enough to not cause turbo problems. I assume that is waht could happen if I kept driving my normal 80mph. I will look at the intake manifold tomorrow. Do I need to remove the fender liner at this point or just take a look around from intake to intercooler? Going to do some more research now. THanks for all the quick help.

You aren't going to do any harm to the turbo if you popped a IC hose. You'd also have a REALLY hard time maintaining 80mph with no boost, lol.

Start at the turbo and work your way towards the EGR/intake.. My guess is that one of the lower hoses let loose.

 

[jbleu101]

Oh, ok....I thought because I could hear the turbo a bit louder that I could cause some damage to it. I am going to try to get it in a shop today real quick.

 

[fruitcakesa]

Sweet. Glad I was able to keep the temps low enough to not cause turbo problems. I assume that is waht could happen if I kept driving my normal 80mph. I will look at the intake manifold tomorrow. Do I need to remove the fender liner at this point or just take a look around from intake to intercooler? Going to do some more research now. THanks for all the quick help.

No you don't.

 

[jbleu101]

Thanks Guys. That seems to be the problem. Got it all fixed and buttoned back up today. ONe last thing, from the intercooler I have a 1.8T pancake pipe, then a silicone connector I bought based on a recommendation from this site. My question is about the next piece....it has a metal male nipple, for lack of a better term. That has a green rubber o-ring on it. Because of the 1.8t pancake pipe it causes that piece to kink a bit before the piping works its way along the firewall. Is there a good replacement piece to go from the pancake pipe to the pipe that runs along the firewall?

 

[Bob_Fout]

Be aware driving your TDI hard with a charge hose/pipe off is not a good thing. You can overspeed the turbo. The ECU is trying to make xyz bar of boost, and it'll keep trying, adjusting the VNT vanes, spinning the turbo more and more to try to make boost.

 

[jbleu101]

Thanks Bob, and all. I don't know which way the flow is on the intercooler, but I have the 1.8t pancake pipe, then a silicone connector that goes into the line with the metal clip connector. That was where the separation occured. I think I am going to go back to the OEM pancake pipe, as Jeff at Rocketchip told me it is really not a restrictive point. Then I will replace any connections from the VNT17 with this.... http://www.idparts.com/catalog/product_info.php?products_id=602
After that I will start a thread to sell my pancake pipe to someone who actually is trying to make a lot of boost. Thanks again for all the input and help. It saved me a bunch of money when I went to the shop with the diagnosis, the location of the problem, and I did the disassembly with the shop owner until his mechanic got there. I let him put it back together because, well, I basically suck at putting stuff back together! It's running great, and I was sure to drive it gently with the broken connection. Thanks again!