Exhaust smell, down on power...

[Sirocco20348]

SOLVED:

Hey guys, I've reached another milestone problem.

I have two symptoms to work from.

Exhaust smell when driving, also I am down on power at wide open throttle, the car is not reaching maximum boost. The higher the gear the more noticeable the power loss.

I have boost leak tested the car and there is a faint hiss coming from somewhere, But doesn't seem to be a hose.

TLDR UPDATE:

• Hiss was identified as leaking injector seals and injector cups via boost leak test with soapy water. Replaced with aluminium injector cups and slightly bigger o-rings. This did not solve lack of power.
• Brand new set of Bosch injectors. Fuel rate must have been limited. See final post.
• Tightening of waste gate with helper springs holds power, not sure if essential. 6psi cracking.

Read the thread for the full journey...

[Sirocco20348]

I did some vagcom testing last night.

Firstly no errors in engine module.

However, I logged banks 002, 007, 008 during some 3rd gear wot runs to 7000rpm.

Valve duty was consistently 99.5%, which indicates a boost leak somewhere in the system.

Super frustrating, I'll be keenly interested to see where this mongrel leak is, it's not obvious.

[jmcc]

I might go log these blocks on mine.
Good luck searching, boost leaks are such a pain.

[Sirocco20348]

I might go log these blocks on mine.
Good luck searching, boost leaks are such a pain.

I'll post up my results so you know what your looking for tonight.

[Sirocco20348]

Linked is my logs...

https://1drv.ms/x/s!ArCKuFTQ_s3egZ0Yl261TOHF9VXbog

Group 002 has my idle speed... colour coded for ease of viewing.

Group 007 has the valve duty... always 99.5% throughout the rev range.

Anyone else notice anything interesting?

[Sirocco20348]

Update: I had my car smoke tested for misc leaks. One was detected/fixed and improved performance. But unfortunately my car still cannot reach requested boost and my car still stinks of fumes...

Has anyone had the 3 turbo bolts come loose?

I am reading a thread where they come loose all the time for various people, especially when modded parts are introduced and vibrations are increased.

This thread!! :

VWVortex.com - TURBO TO MANI Bolts coming loose??

When I put my hand down next to that gasket when cold I totally feel like there is air escaping from that gasket, but it's such a pain in the ass to tighten those bolts. I will have to remove the charge pipe...

Please anyone chime in with their 5c worth.

[Umai Naa!!]

Yeah, totally plausible.

You'd have to at least replace the gasket and bolts. Given the age, they'd probably break if you re-torqued them, and the gasket has probably blown out anyway.

As for a solution, high-temp Loctite seems like it'll do the job.

[Sirocco20348]

Yeah, totally plausible.

You'd have to at least replace the gasket and bolts. Given the age, they'd probably break if you re-torqued them, and the gasket has probably blown out anyway.

As for a solution, high-temp Loctite seems like it'll do the job.

Well the turbo was a new install about 45,000km ago with all new hardware. Do you think I could give tightening a go?

As for thread locker, which one is appropriate for turbos?

Maybe I should just buy one of those fancy ninja stars/ turbo locking flange if needed

034Motorsport - 034-R01-8005 - K03/K04 Turbo Locking Flange - priced each

[jmcc]

I don't think there's any version of loctite that will work on an exhaust manifold, even ultra high temp is only like 350c.
You could use lockwire or locking bolts they're a pain though. I don't get how the ninja star works, seems like it'd just be a fancy washer. That bolt closest to the block is the worst to get to even under the best circumstances.

[Umai Naa!!]

Look into tab washers.

You bend one tab over the hex of the fastner, and the other over the edge of the flange.

[Sirocco20348]

I don't think there's any version of loctite that will work on an exhaust manifold, even ultra high temp is only like 350c.
You could use lockwire or locking bolts they're a pain though. I don't get how the ninja star works, seems like it'd just be a fancy washer. That bolt closest to the block is the worst to get to even under the best circumstances.

Tbh I just finished pulling off the charge pipe and testing the bolts, they are not loose at all, easily exceed the torque requirements.

I honestly have no idea... All I'm thinking of doing is replacing all the gaskets associated with turbo and exhaust manifold....

Maybe I wait until the subframe is dropped out for all of them as I don't know how anyone has room to get to the exhaust manifold bolts...

[jmcc]

maybe, get one of those household carbon monoxide sensors? If you've got exhaust leaking out that should pick it up.

something like this New Carbon Monoxide Meter with CO Gas Tester Monitor Detector Gauge 1000ppm I9N2 714424467812 | eBay

[Sirocco20348]

maybe, get one of those household carbon monoxide sensors? If you've got exhaust leaking out that should pick it up.

something like this New Carbon Monoxide Meter with CO Gas Tester Monitor Detector Gauge 1000ppm I9N2 714424467812 | eBay

This looks pretty cool.. I might buy one to see if it's accurate. Would be good if it came with an extendable neck...

I have bought seafoam as a test, apparently billows snow from exhaust leaks..

I'm thinking the turbo and manifold needs to be removed and inspected very carefully for problems...

[Sirocco20348]

Farout I'm almost over owning this car... Replaced turbo to manifold gasket. Old gasket was fine and the bolts were tight.

That strong exhaust smell is still present at WOT.. maxing out at 15psi. Very unimpressive for stage 2.

I'm thinking of replacing the brake booster line as it's been patched up over time.

Apart from that I'm not sure... Heaps of threads on the internet with mystery boost leak problems.

Sent from my LG-H870DS using Tapatalk

[Umai Naa!!]

What about manifold to cylinder head?