2.5TDi V6 quattro Sport 180hp Turbochip

[fjtwelve]

St austell? Thats getting dangerously close to home. Let me know if you fancy a pint. I'll track you down by following the blue haze of 2 stroke.... provided mine hasn't blown up again by then.
I have been thinking about this and oil in general. I started running the FJ on 20-50 instead of 10-40 when it started getting on a bit, less oil loss through shall we say a well run in engine, and cooler running. Wondering if i should try it on the car.

 

[HerefordQuattro]

Staying at Petewan Sands (again) near Mevagissey - where are you?

 

[fjtwelve]

30 miles away in Falmouth. It'll take longer to find out which one of the 100 pitches/homes you are in than drive there. Either that or i'll just stop outside and you can look for the plume of smoke.....
Know where it is but not where the best pub is.

 

[fjtwelve]

Fired home last night (wedding anniversary needed to pay off brownie point overdraft with surprise visit) and back this morning, basically caned the ars3 off it wherever possible both ways. Have found that it responds to this, especially when changing down hard into roundabouts and bends and pushing the engine braking from high revs. By respond i mean that i'm getting more boost for longer and not smoking until the upper end of throttle opening and revs. However dooodling along at any speed below about 85 ie engine not under load seems to allow it to revert to snooze mode and then when i give it stick i get smoke and limited power and revs for the next few miles and then it starts performing a bit better. I am still only rarely getting back to the original performance though. Never a dull moment eh

 

[Billyboy200uk]

Fjtwelve, came across the start of this thread 2 days ago, and feel that I have been reading a novel. Can't believe all the trials and tribulations you have been through in the last 5 years.....been amazing diary to read. Did you ever get anything sorted with regards to Heathrow Engines, or just chalk it up to bad experience?
The 2 garages you have been using since you have been in the west country sound like absolute stars, can't believe they have charged you For ALL the hours they have put into your car. Felt really bad for you with all the woes you have gone through, not to mention the amount of miles you rack up.....tyres me out jus reading about them all !! Lol.

Anyway mate, REALLY hope you get to the bottom of your problems, I think, had I been in your shoes, I would have thrown the towel in years ago, and replaced the car, but respect for your dogged determination all these years.

Will keep following the saga

All the VERY best

Dave

 

[Inskip75]

ok first report - arrived home from Brands last night 564 miles and 37.7 mpg ave on m/way all way - engine seemed smoother (until DMF decided to get worse on M25 car park) and a little bit more responsive and able to pull from slightly lower revs. Don't think I am imagining all these but you know how it is

Economy seems very slightly better but engine less rattley on first start. Used Shell 2T 'cos I was at my usual garage filling up but at over £13 for a litre will do some more planning - Carlube off ebay looks the best buy, not quite as high spec as Shell but don't think its that important. I'm also going to check B&Q for Ryobi as thats quite cheap.

Put 700ml in first tankful bit more than wanted and put rest in at Brands when topped up so first tank a bit richer than normal - will drop to 300ml for full tank from now on.

Not sure about exhaust smoke - I will give it a some stick one evening this week with headlights behind to see if its improved - mines not that bad as redlined regularly but may be able to see a difference.

 

[fjtwelve]

So you wanted some Race 683 nozzles like mine? Form a queue here (yes i have replaced all my personal details with fjtwelve i know this thread has a lot of followers but i am not yet able to write to the factories under my pseudonym (word for the day)):
From: Diesel Levante Srl - Export [export@eturbo.net]
To: fjtwelve
Cc:
Subject: R: Fratelli Bosio Race 683 nozzles

Hello ,
available at 42.00 euro each .
Thank you .

Angela Iacovelli

Working Hours : 08:30 - 14:30;
For urgent requests from 14:30 to 18:00 email to : info@dieselevante.com

diesel levante
70026 Modugno - S.S.96 KM.116 - Italy
phone 0039 080 5357615 (ext. 7) - Fax. 0039 080 5357579
http://www.eturbo.net - info@dieselevante.com

Da: fjtwelve
Inviato: giovedì 1 settembre 2011 23:14
A: info@eturbo.net
Oggetto: Fratelli Bosio Race 683 nozzles



Please can you tell me if you are able to supply Fratelli Bosio Race 683 diesel injection nozzles for use in VAG 2.5TDI engine code AKE.

fjtwelve

 

[fjtwelve]

Blew a coolant hose yesterday down behind the aircon unit at the bottom of the engine (well it would have to be in an inaccessible place for me wouldn't it). AA relay back to falmouth. Recovery truck driver wrote down the odometer reading then had to go back for another look to check. AA keep me mobile have provided a Seat 2.0tdi free for 3 days, seems handy enough. Otherwise still smoking and going unpredictably. Planning to arrange things so i can have the injectors out and the turbo off for checking but lifes too busy atm.

 

[fjtwelve]

That'll be the form of hose thats actually the water pump then, water was leaking out of there and running down around the hoses at the bottom. Front of the car is off again (mechanic just whistles now and it jumps off on its own). This could be the straw that breaks the camels back lads. I'm going to have a last go at fixing the smoke problem and then its off to the sales i think.

 

[fjtwelve]

Who closed the thread then? Don't remember doing that. Water pump is fixed, usual 10 to one labour to part cost ratio for anything around the front of the engine. Going home on the train tomorrow sigh 90 mins to get to the station plus 5 hours of joy followed by getting a lift home. I'd rather be smoking diesel than that.

 

[fjtwelve]

The miller diesel additive may have made a difference over 10 tankfuls or so, i was double dosing and looking back over my notes it may be freeing off slowly. So having run out of that a couple of tanks back i dumped a bottle of STP cleaner in there yesterday and have been driving around one or two gears lower than necessary to keep the revs up. Yesterday once i got it hot and revving it was running happily between 3-5k rpm in 4th and the smoke was pretty minimal. However it doesn't last, as soon as the revs drop and you're faced with accelerating from low revs up a slope it smokes again. Once thats through we'll go back to double dosing the Miller for a bit. Maybe i'll try the Mr Muscle oven cleaner on the exhaust side of the turbo if that doesn't get things sorted.
I have been driving a few other cars in anticipation of changing this one in the next few months. So far i have crossed off my list the S4 (great when you get it going except the 17mpg when you do) BMW520 (2.2 litre engine gutless)BMW 320D (too slow) BMW330D ( have to drive hard in sport mode to get any kind of oomph) BMW525i (the one with the 3 litre engine, just too slow even in sport mode) and A6 2.7TDI (too slow). The only thing thats got the right feel is the A5 3.0TDIq Tip, and Celtic can remap to near exactly what i've got now well maybe a bit less torque. Unfortunately expensive though. Only good thing is the numbers that the dealers reckon i could sell mine for. Need to get this poxy smoke sorted.

 

[HerefordQuattro]

3.0tdi has got to be the way, guy on the rolling road day when i had mine chiped got his standard A4 3.0tdi up to 296bhp and too much torque just from a chip ;-)

 

[swarcup]

Just done the mr muscle turbo clean on my turbo this weekend and it deffo works, No hesitation anymore from sticky vanes. All in all it only took an hour and a half.

 

[HerefordQuattro]

Just done the mr muscle turbo clean on my turbo this weekend and it deffo works, No hesitation anymore from sticky vanes. All in all it only took an hour and a half.

did you take the turbo off to clean it? i thought the Mr Muscle was only safe for the 1.9 as the 2.5 was mounted differently?

 

[swarcup]

Nope i left it on, i removed the heat shield and the exhaust off from the right side of the turbo and filled it until the foam came out from behind the blades. I was aware of the stuff getting into undesirable places so used it sparingly and only left it for an hour working the actuator and blades, after working the actuator a couple of times it did start to move more freeley. Went for a blast and the difference was there straight away. i have done a couple of hundred miles since doing it and there are no differences in how the engine is running or sounding. all good so far

 

[fjtwelve]

Did the Mr Muscle treatment this morning, easier than i thought , left it in for an hour. Took the spray nozzle top off the Mr Muscle tin and stuck the top off a WD40 tin on so i could use the WD40 tube to get inside the turbine housing. No noticeable difference yet having driven up to Truro and back. Maybe a bit cleaner exhaust below 3k rpm, but no sudden return of torque or free revving. Can only move the actuator up and down by firmly gripping the arm with pliers and pulling and pushing hard up and down. Theres also soot under the actuator between the inlet and exhaust housings. I think i'm in for another turbo. Now i know how easy The Mr Muscle is to do i'll maybe do it again before opening the wallet.

 

[fjtwelve]

OK i take it back there has been some improvement, getting unpredictable torque below 3k, will rev to 4-4.5k sometimes, sometimes its there sometimes not, but still smoking. Will definitely be re-doing the treatment.

 

[PAULF]

I had a couple of goes at my car with the Mr Muscle before I got the vanes clear.
The treatment will work better if you take off the turbo and really soak the thing through the exhaust feed, but feeding the pipe in through the vanes in situ seemed to work ok for me - see my reply on Evilscotsmans thread.
You can check the actuator with VCDS Basic Settings 11, which moves the arm up and down every 10 seconds in a similar manner to the timing check. This lets you see if you get full travel with the vacuum. Keep treating the turbo until the arm moves all the way under its own power.
Forcing it up and down seemed to help break up the carbon, but beware, I suspect therein lies a possibility of damage.....

 

[HerefordQuattro]

OK i take it back there has been some improvement, getting unpredictable torque below 3k, will rev to 4-4.5k sometimes, sometimes its there sometimes not, but still smoking. Will definitely be re-doing the treatment.

Can you take a couple of photos next time you do the treatment to give us novices a bit of a clue please - I'm keen to do this myself when i get the time

 

[fjtwelve]

OK will do (just had to have the 500th post)

 

[HerefordQuattro]

OK will do (just had to have the 500th post)

congrats - epic thread now!

 

[fjtwelve]

Click on the pics for larger versions Start...........turbo at back........10mm socket.......turbo.....take off egr pipe for room

 

[fjtwelve]

12mm ring spanner, cloth to catch nuts and Mr Muscle over spray, pull exhaust away from turbo, fit WD40 cap to Mr Muscle tin, oops look at that soot where it shouldn't be, squirt mr Muscle into exhaust turbine housing

 

[fjtwelve]

Slightly too much Mr muscle in there, bent piece of wire to insert into exhaust turbine and GENTLY rotate the turbine, insert the pliers around the actuator, grip and move up and down, put the exhaust back on the turbo

 

[fjtwelve]

Fit the heat shield back on, refit the egr pipe, refit the engine cover, wait for an hour, restart the engine and go for a drive. keep an eye on things to make sure you tightened it all up.
This is the second time i've done it. Benefits weren't immediately apparent the first time, but by the time i was on my way back from London ie had done maybe 300 miles of motorway and town driving, there was a distinct improvement. Again not much immediate change this time (theres also a service just been thrown in to upset things) but we shall see.

 

[boya]

Loving this thread!! Great instructions too mate!

 

[fjtwelve]

Fuel economy has climbed above 30 for the first time in months, gnats under 500miles on the last tankful, the soot level on the back of the car has dropped right off. Still hesitant over 3000rpm but revs if i catch it right so will do it again.

 

[boya]

Just done the mr muscle trick today on my 2.5 aswell as blanking the egr valve off and all I can say is WOW!! Feels like a new car!! More torque lover down in the rev range and pulls like a train all the way through! There was no black soot cloud from the exhaust when I gave it a thrash so am going to repeat this again next week sometime, make sure that I got it all, as for mpg I don't have dis so couldn't tell you if it has improved.

 

[fjtwelve]

back to the AA and the garage again. Wouldn't start, coaxed with easystart about 4 or 5 times over last 3 days but drove to London no problem, then this morning folded its arms and refused. Fuel pump in tank is starting but cutting out 3 secs after turning the ignition, theres a relay for the pump under the dash that clicks in when the ignition starts, and then something is causing it to click off again. result no fuel to fuel filter. aa bloke after working through all the same checks as i did says " you know quite a bit about this car then?" mebbe but obviously not half as much as i need to. Just as i was getting all excited that it was showing signs of getting back to its old self again

 

[fjtwelve]

Sky News got Heathrow Engines (in their latest incarnation) . Nice chaps as you can see.

Garage implicated in defrauding hundreds of customers and threatening physical violence - YouTube

Made my evening.

 

[HerefordQuattro]

nice chaps!

 

[fjtwelve]

First off Airport Motors replaced the fuel tank pump. Was a bit surprised as its only 18 months since we did that one. Car started, its fine they said. Went round to pay, got in the car, 5 secs later it cut out. Next day replaced the fuel filter, suspect air leak at fuel filter on the non return valve. That seems to have fixed it. Not convinced I needed a new fuel pump but wasn't standing next to them to check it, and the old one got skipped.
Anyway smokes like **** all the way home, fuel economy pants. Gave it the Mr Muscle treatment 3rd time, spanner time now down to 15mins. Noticed dribble of diesel on top of fuel filter. Not a great improvement initally but got steadily better as i got closer to London this morning. Is now pulling strongly to 3k, will rev beyond, but smoking at wider throttle openings.

 

[adamss24]

Martin, i suggest you take the injectors out and increase the pop pressures and get them balanced- get a diesel specialist to do it for you. That's the most plausible explination for your lumpy iddle and smoke under low revs as the pilot injections are all over the place...You'll melt the piston crowns if you carry on driving with wrong pop pressures, i wonder what your EGT's are on full throttle ?!

 

[fjtwelve]

Yes thats what i'd like to do, i've had it on my to do list for months, its just finding a time to do it as i'm up and down to London all the time. If i could find someone in London to do the whole job in a couple of days i'd be sorted. How're you fixed?
EGT at full throttle? Yes i remember full throttle. With this smoke problem and its inability to rev out i have not been there for a long while. I don't know if i've got a turbo problem or its just full of carbon. It definitely gets better after Mr Muscle, so i will repeat until no discernible difference. Then i need to find a 4WD dyno that can give me a data log or find time to go back to Plymouth. Then get a remap based on the dyno read out.

 

[PAULF]

The problem is, if you are producing loads of smoke, you will gunk up the turbo.
If you can sort the smoke, then you wont have to Mr Muscle it again.
I would be wary of using Mr Muscle too often, in case it causes other problems.

 

[fjtwelve]

I know, i know, hence the last 8 months slowly replacing and cleaning everything working my way slowly toward injectors and turbo which are like as not going to be expensive. I've pretty much eliminated everything else now, and i know it goes much better when the turbo is cleaned out (went out for a drive last night, much better) so i know thats not the whole problem.

As i said above, anybody know who in London can do the injectors for me? Overhaul and pop pressures to be reset - any advance on 240bar?

 

[fjtwelve]

Going like a good un now, pulling very strongly below 3k rpm and revving to 4 in lower gears, smoke much diminished although difficult to see exactly under streetlights.

 

[kernow]

Hi fjtwelve
I have been reading this thread on and off for the last 12/18 months and have thoroughly enjoyed it, I really admire your determination to get the problems sorted, and they seem to come one after another these days, probably the high mileage may have a factor on some of them.
Like you I run a V6 2.5 tdi but mine is in the form of a late 04 Passat Estate, last of the old shape model and has only done just over the 100,000 mark so hardly run in yet.
I also have a couple of add on's to improve things a little in the form of a german DTE tuning box which gives around 30bhp increase a water/methonal injection system and the customary K&N filter change and thats about it. It goes extremely well very torquey and will easily return 45+mpg on a run with a regular 40----ish locally.
The only downside to it all is the amount of smoke it puts out, I give a good blast from time to time to clear it out especially if her-indoors has been "poodling" around locally for a week or so, and when I do it fills the road behind so much so you cant see for a couple of hundred meters or so until it clears, but it is always there when the boost comes in.
Anyhow to the point, I have recently been reading a lot about the adding of two-stroke oil as an additive to your diesel tank, with I have to say very favourable results, so I decided to try it last weekend I didn't know the recommended ratio then which is 1:200 so guessed it at about a cupful to around 45/50 liters which was rougly what was in the tank at the time, turns out I wasn't too far out.
After running it now for a few days and adding around 150miles to the car it's amzing the difference it's made the car is so much smoother, noticebly quicker and the best to come the smoke as dissapeared just about completely, oh and apparently you get an improvement in mpg, which remains to be seen but I'm optomistic.
By the way I'm just up the road from you by around 10miles give or take a yard or two near Redruth.

 

[fjtwelve]

Water/methanol injection? Yes go on, you can't throw away a line like that without more details.
Yes going to give the 2 stroke a go. Will report back.
The car seems to be back like it was 6 months ago, i have intermittent full on power and no smoke. seems to go best when fully warmed up and constantly accelerating and decelerating. A lot easier to drive around town, i went into central london again this week without being juddered to death at idle. Is much more willing to go now, have had one incidence of looking down and finding i was doing 100 without realising which hasn't happened for a while. is running out of puff at around 120, so not fixed.

 

[boya]

Water/methanol injection? Yes go on, you can't throw away a line like that without more details.

I will second that!!