Cupra TDI turbo issues - slow spool

[killbot]

I've recently been experiencing problems with my turbo not spooling up nearly as quick as it used it to and I am trying to figure out the problem.

I have had a look underneath and found a split hose from my intercooler which I have patched up for now but I'm still experiencing these problems.

I've noticed quite a lot of oil residue build up on my intercooler on the right hand side so i'm guessing that it may be leaking...

I've also noticed a lot more black smoke coming out the back, especially at higher boost pressure.

My boost gauge is showing that it is holding boost well when it finally reaches its peak but it just takes longer to reach it.

Would boost leaks cause a slow spool or could it possibly be a VNT issue?

Thanks

 

[R3k1355]

If you've found some leaks and the IC is covered in oil then you've certainly got some boost leak issues.

You need to sort those before looking elsewhere for issues, if the cars heaving out soot then you can cause yourself even more problems by clogging **** up.

So stop driving it and fix the problem.

 

[mgrays]

Hum.. turbos will breath more heavily (more pressure gets past piston rings under boost) and the intakes clog up with oil. Higher mileage means it happens more. My Intercooler has more than a couple of pin holes that leak oil. Car also does visible smog under a heavy foot but it has been chipped... when I had the hose into the intake half out (i.e. leak) it would actually obscure the rear view mirror .. so I knew it was bad. If I am being good I wash out the inlet system completely every 20-30k miles to get the oil out.. anyway there will be a bit of oil and a bit of smog .. but the EGR will choke up inlet as it reintroduces raw carbon into the inlet which cakes up with the oil to make a right old mess. Go through the hoses again ... it can be hard to see where the hole is .. but it maybe the turbo vanes jamming also.. best of luck!

 

[killbot]

thanks very much for the reply, gonna have a good check of the whole system and give the pipes and intercooler a good clean so I can get a better idea if there are any more leaks anywhere

 

[R3k1355]

Could be leaking from the top intercooler hose, a leak there would cause oil to drip down and cover the IC.
Could also be a hole in the IC or something too.

You might have to clean it up, then run it down the road and back to see where the leak starts.

Be thankful tho, at least when a diesel has a boost leak it usually pushes abit of oil out with it.
No such luck on a petrol, you've gotta scrutinise every join very closely, can be a right ball-ache

 

[killbot]

Cheers mate.

Had a good look over it all yesterday, had the intercooler off and cleaned it all up and filled it with water. No obvious leaks.

Found a split hose going to the intercooler which looks like it was the root of my problems. Patched it up with superglue, a puncture repair kit and duck tape , hopefully that should hold until I can get some uprated pipework.

Thanks for all the help guys

 

[killbot]

just finished replacing all the pipes with darksides hard pipe kit

very impressed with the results, definite notice a performance gain and the car just seems much better all round

Was a bit tricky to fit everything, did an egr delete as well so had to blank the egr at the exhaust manifold which proved to be a bit tricky.

But after some hacking away at the front bumper all pipes were on and the car is now runnign beautifully

Definitely recommend the pipework on a cupra for anyone who is on the fence about it

 

[mgrays]

My lower intercooler pipe also burst.. similar results i.e. more black smoke at 1500-2500 rpm than usual and a "bit" slower. It was throwing engine code and going into limit mode a lot more than normal.. the usual "on cruise control up decent hill" trigger was doing it more.

The OEM hose to lower intercooler port from turbo, that fits to intercooler is 6LL145832 and is £50 and at least 2 weeks from Spain from dealer. I did look at other kits but all require you to hack up bumper and are generally not as well secured to body... plus cost £225 min (Darkside). These hoses are only fitted to this car as that intercooler is special for Cupra TDi

My solution was £15 hose delivered in 4 days from MK Performance on ebay. You need to order a 45 degree hose with 60 -> 57mm ends. Cut about 30mm off each end and it fits right in. You can actually see this hose through the grill is you look and mine had a rip that was about 40mm long which I too bodged with good gaffer tape for the week it took to get mine (Saturday order, Thursday arrival) which worked .. it was squealing under boost so I was taking it easier.

Actual hose ends dimensions are 56-59mm and 59-63mm where the first number is the pipe outside diameter and the second is the diameter of the ridge on the outside of the pipe. So these are not hose diameters but the pipe that the hose goes over.

Hope that helps someone. This was a 2005 Cupra tdi.