White Smoke, broken intercooler

[VChristian]

Without covering the full saga, I have an 02 Jetta which is blowing lots of white smoke (fuel, not coolant). It has an intercooler which has blown apart (o-ring hanging from it), and is giving me a 19561 code. While I work on that code, I thought I would see if the busted intercooler would be the cause for the white smoke.

Also, at 2000 RPM, with a fixed throttle position, the engine surges 300 to 400 RPM. Is this perhaps because of the large opening in the intercooler, or is that likely unrelated?

Any ideas?

I am sure I will be working on this for a few more hours.

edit: It seems that the white smoke could be because of overfueling, as the leak in the intercooler will cause the MAF to have a higher reading. Not sure on this, but will attempt to see if I can fix the intercooler...perhaps epoxy and duct tape or some such silly thing, until I can get a new one in.

 

[Jake_S]

Replace the intercooler, then determine if you have another issue. A boost leak is not healthy for the engine, nor your wallet.

Jake

 

[VChristian]

I now have the intercooler out, and will be replacing it. However, I am trying to better understand things, so that if there are other parts I should be getting I can order them now, rather than put in the intercooler, and find out that I need a other item which may take another 5 days to get here.

Besides, I would rather understand things than just replace parts.

 

[wonneber]

Broken Intercooler

I now have the intercooler out, and will be replacing it. However, I am trying to better understand things, so that if there are other parts I should be getting I can order them now, rather than put in the intercooler, and find out that I need a other item which may take another 5 days to get here.

Besides, I would rather understand things than just replace parts.

Is the O-Ring hanging out the only problem with the intercooler?
If its not physically broken I do not see a reason to replace it.
Rock Auto may have it if you check the web site or a local hardware store or supply house may have something close.
It only prevents air from leaking out in my opinion.

Rich W.

 

[VChristian]

The plastic on the intercooler has separated from the core, across 3 of the four attachment planes. There is more leakage area than there is inlet area by 10X.

 

[VChristian]

BTW when the leaking intercooler was replaced, the smoke issue was resolved.

 

[Nevada_TDI]

To back up what Jake S has said if you don't already know: a major leak on the pressure side of the engine--turbo discharge--can cause the turbo to go into over speed as the ECU keeps calling for boost and does not get it. Over speed = turbo death.