Boost Leak! HELP!!!

[Rich___Cupra]

Hey guys, I have a serious problem with my Cupra I was hoping someone could help.
To start I have a 05 Ibiza Cupra TDI have it nearly a year. Love it, excellent wee car, nice on mpg and shocks a lot of people with the kick it has. I have had it remapped to 190bhp and 290ft/lb. had no bother with it for months driving like a dream.

So the problem begins, last month i noticed a drop in power, was still driving ok just not a quick as it used to. So I ordered the piping from the turbo 'twisted S' shape as it looked as it needed replaced. New part in no joy, thought to be the intercooler then, waited til payday and ordered that. In the time the intercooler came the day before it was going in the turbo blew!!

So turbo now reconditioned and back in, new intercooler in checked all piping with carb cleaner (I think, it makes the engine rev on its own if it gets into the pipes) everything good and sealed, even put it on a ramp to check all piping is swelling up in the boost which they all are. Took it for a spin last night and still the same problem, loss in power, hiss coming from the engine.

Please help guys I'm running out of ideas and it's killing me. I don't want to drive it i case the turbo goes again and that was not fun!
Only thing I've left is the mounts in the engine, there is a knock probably the gearbox mount but I've lived with it, it sounds like it has got worse, is it possible that when the engine is under pressure and the mount not doing its job that the movement is dislodging a pipe at the seal causing a leak?

I've just run out of ideas, sorry for it being so long winded, any ideas or help welcome.
Cheers Rich

 

[Badger]

If you're sure you've check the whole intercooler system including pipes, take a look at the EGR valve and cooler for leaks. Also unplug the MAF on the inlet just left of your airbox and see that improves things.

 

[Rich___Cupra]

Cheers for the speedy reply, i'l do that shortly and leave an update.

 

[S7UYJ]

To be sure, try using tpfe tape(I think! Thin white tape for sealing plumbing connection) around the male joints on each pipe, I had loose fitting pipes and that solved it fine

 

[Rich___Cupra]

Each pipe! Aww nightmare!
Will try that after I try the egr valve, need to get the vacuum machine to test it, will try and get it for tomorrow.
Disconnected the MAF and it just felt like i had no turbo at all, flat.
The list goes on....hope it's sorted soon.

 

[Toby Davis]

Had loss of power on my cupra tdi on to occasions

1st - down on power, it was there but not what you would expect for 160bhp - problem - butterfly flap had come lose in egr and blocked air flow apart from the 2 small holes where it was meant to be attached.

2nd - complete loss of power - problem - something had gone in the ECU - £350 to fix - if this was the case for you, you should have at least 1 or 2 warning lights on your dash.

Other wise check EGR ist blocked as said, fuel filter blocked perhaps, if you had an air leak you would hear it, faulty vaccum box if that effects your boost ? If you cant find a fault in the pipe work anywhere i would be inclined to say it could be electrical.

 

[Rich___Cupra]

I can definitely hear air escaping just have no clue how.
Also to add the car is going into limp mode and the engine management light is temperamental with coming on.
Don't know if that makes a difference.
Starting to worry there may be a leak in the new intercooler at this point I'm guessing anything is possible.
Egr valve to be checked in the morning hope it ends there....

 

[Lavery]

Good old soapy water test... Spray it on all the joints, start the car and look for bubbles.

 

[S7UYJ]

Jus a thought, waste gate stuck open? Or part open? That would reduce power, make the air escaping noise and possibly throw a light up because the maf is reading more air going in than your actually getting

 

[dann2707]

They don't run waste gates mate, they are of the VNT type.

http://www.briskoda.net/forums/topi...treatment-thought-we-needed-a-guide-of-sorts/

I'd try that though as the veins can get stuck

Sounds like a boost leak though, try making a boost leak tester! Lots of guides on the internet.

 

[nuggo]

Ive been having similar issues on my Cupra for about 12 months now.

Persistent hissing under load (almost like a digitized whistle) but its never taken me to limp mode.

Have replaced almost every turbo pipe in search of the issue but no avail. Stripped and cleaned the EGR/butterfly the other day thinking there might be something going on here and put back together using RTV sealant to make sure. But the problem persists!!!

Anybody here used this Mr Muscle technique?

 

[Lavery]

How about the gasket between exhaust inlet and the egr itself? Could that need replacing? I was running without one of these bolts for a couple months as I dropped it in to narnia... As a result, pressure differences caused car to go in limp mode once... It also squealed like a pig on boost.

 

[Rich___Cupra]

Found it!!!
3 hours at it today such a relief to finally get it motor back to normal, over 3 weeks on the limp!
It was in the pipes, the plastic one which is under the driver side headlight, it had a small split in it.
The reason why the carb cleaner didn't pick it up was because the split was at the back of the pipe, had to take off the bumper and then the steel bar thats directly behind the bumper, nightmare really.......

Cheers guys for all your help and replies!

 

[Badger]

Glad you got it sorted!