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Maybe Blocked CCV causing smoke and turbo lag with pics
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Author:  damo4runner [ Tue Aug 04, 2009 6:37 am ]
Post subject:  Maybe Blocked CCV causing smoke and turbo lag with pics
Hi there have had recent smoke issues which are out of the normal type, cleaned boost sensor, changed fuel filter, air filter, oil filter and oil, Still getting large amounts of smoke on take off when cold supper bad when having to idle at the stop sign at the end of the road about a mile from start up, greyish/black in colour changing to black when warmed up fully, hesitates on take off and feels a little down on power in general. Highway is fine but was beaten off the line buy a dump truck while I crawled then blew big smoke as turbo kicked in (not normal).

So clean boost sensor again today 1000miles (1600klms) since last cleaned was black but not crusted up supper thick. Anyway noticed oil and dirt/road grime on top of engine (see pic below) Oil leaking from somewhere my thoughts are the CCV there is oil down the side of the engine but I would think oil runs down hill (gravity) so the oil around the bolts and the the block lower down is coming from up top (I think). Other side of engine is clean no oil or road grime. Boost hose on right side (airbox side) is covered in same crud down low near connection. Question is can you take a CCV apart and clear a blockage or is there something else I am missing, no provent yet, yes I am slack. Could this be causing my lag and extra smoke or am I barking up the wrong tree.

PS I'm in Australia 03 model standard turbo NO VGT no FCV from what I can see either.

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Author:  Joe Romas [ Tue Aug 04, 2009 7:08 am ]
Post subject: 
Looks like a split in the boast hose to me where the oil is leaking. It would also explain your poor preformnce. Also you didn't mention your air filter :lol:
Author:  tonycrd [ Tue Aug 04, 2009 7:16 am ]
Post subject: 
Yeah, that's what I was thinking...take of the boost hose and check it for a crack.
Author:  damo4runner [ Tue Aug 04, 2009 2:58 pm ]
Post subject: 
Shall do but what about the oilyresidue near and on the CCV that is a fair distance from the Boost hose and no oil on the parts that are inbwteen also yes I changed the air filter I had an amsoil one but replaced it with a factory new one just to rule that out also. Can I degrease the engine and tryy and see where it is coming from will the washing process upset anything in that area?
Author:  kelticknight [ Wed Aug 05, 2009 9:48 am ]
Post subject: 
wheres the boost hose on his pictures
Author:  linewarbr [ Wed Aug 05, 2009 10:22 am ]
Post subject: 
In the top picture, running along the left side from top to bottom. That is the turbo-to-intercooler hose.

There is a lot of oil sludge around the CCV and on top of the valve cover around it, but if it was coming from the CAC hose, it would be everywhere, not just there. I would have to guess the CCV itself or the hose leading from the CCV to the intake is blocked or torn. That would be doubly bad because then your turbo could be sucking in unfiltered outside air. It kind of looks like the oil is spraying back on top of the puck from the hose.
Author:  nursecosmo [ Fri Aug 07, 2009 2:53 am ]
Post subject: 
Things to consider: if the CCV were plugged, the main seals or other similar engine seals would have blown out. Also the OE hoses would sweat oil very badly, and would build up a nice coating just like you have now. We can see from your nice pics that you have not removed the CAC hose for inspection. That is the ONLY way to properly inspect it, and it doesn't take long, It's just very messy.
Author:  damo4runner [ Fri Aug 07, 2009 5:24 am ]
Post subject: 
Thanks for that the CAC hose has been sweating a bit of oil especially on the top of the hose if I wipe it clean it comes back in about a month. I have now removed the hose to the CCV puck and checked it and cleaned as best I could around that area. Also and this is something worth noting that it appears that I have been driving around with an overfilled engine the oil on the dip stick sits about half an inch higher than the MAX mark so first thing tomorrow I am dropping some oil to bring it back down. I have noticed this before but have only yesterday found out about the very slow drain back of the oil leading to false readings when topping up oil. I will remove the CAC hose 2morrow as well and look for any damage or cracks, also going to buy the bits needed to make a homemade Provent.

PS just tracked down a company in the UK that sells the Samco hoses for my model (they are different to the US models). Also what other seals would I be looking for that would have or could leak.
Author:  damo4runner [ Sat Aug 08, 2009 8:26 pm ]
Post subject: 
Ok removed the CAC hose today light coating of oil all the way though it but NO SPLITS at all there is damage to the hose from the outside it has been rubbing against the air box and has eaten its' way though the outer black layer and started into the orange inner layer also been rubbing against the radiator fill/overflow tank but that hasn't managed to get to the orange layer yet. So yes I need new hoses maybe DC ones depending on price cause the Samco ones for my model are only available from the UK and will be about $400 Australian delivered.

Now the bigger problem as you can see from the photos above the CAC hose at the turbo is covered with oil and grime, well removing the hose was easy I think a little too easy I could undo the worm drive clamp by had and the hose had movement before I touched it. Now I have put it all back together with no movement and the clamp is finger tight, then I tightened it up 3 more twists (not to much but just enough I think). I am thinking my boost has been escaping out the bottom near the turbo causing the oil and grime for some time hence my chasing of the excesive black smoke. Will drive it later today and use my seat dyno to tell if there is any improvement
Author:  damo4runner [ Sun Aug 09, 2009 12:00 am ]
Post subject: 
Ok no difference when I drive. I did remove about 1.4quarts of oil and now before I started it (as in it sat there all night) the oil level was half full dead in the middle, anywhoo driving it felt no different driving although smoke was black at an intersection even 2 miles after start up(sometimes it is greyish black). So no leaks in the CAC hose it feels ok but different to how is was say 1 year ago when I could take sedans off the line. No closer to finding out what could be wrong. Please help with any info.
Author:  kelticknight [ Sun Aug 09, 2009 8:54 am ]
Post subject: 
i have simular prob to yours,with it being smokie,at low revs at 1500 revs when i flour it,get alot of smoke,when changing gears,got the injectors cleaned ,helped alittle but still have smoke,checked egr valve,thats ok

get a vw teckie to put on there main test centre pc and everything was showing to ok,air flow,fuel feed,etc
im still looking for a fix,would say its a simple one ,just a gut feeling
Author:  damo4runner [ Mon Aug 10, 2009 5:07 am ]
Post subject: 
WooHoo I'm not alone finally I have found someone with the same problems thanks for the support. Do you by chance do your own servicing? I do and today was told that the common rail injectors need servicing cause sometime they go out of time with each other so I shall start to look into this but from your post I would assume you had this or similar done already. Oh well I shall keep looking.
Author:  kelticknight [ Mon Aug 10, 2009 6:28 am ]
Post subject: 
had injectors cleaned etc,was thinking about getting new ones but with them costing me €647 each and was told by vw teckie ,they are working ok according to computer,might change one or 2 to see if any difference,have samco hoses too,i think think its something obious thats causing this as it happen in short period of time,something to do with fuel system or attached to fuel system,taking to a guy who does rally cars and he might have a idea
Author:  damo4runner [ Tue Aug 11, 2009 4:28 am ]
Post subject: 
I dropped into a diesel mechanic today he suggested turbo or injectors he said they are remove throw away and replace injectors so if you had yours cleaned then maybe your guy knows more than the one I dropped into today (I don't normally go to him I was just in the area and noted a diesel shop figured I would drop in). He said that replacing them would make a big difference as he just did a Ford Transit and the owner was over the moon but the cost is as you say over the top. He also said maybe the turbo could be on the way out but you would have to remove it to inspect and report he said that doing that was a witch of a job (not a 5 minute thing) apart from that he stated that even if the boost was low (probable cause of over fuellng not enough air/boost) the electronically control fuel rail should adjust fuel to suit.

This leads me to think a couple of things:

1. Reset base idle and engine by unplugging battery over night and then reconectting and letting idle for 15 minutes before moving vehicle.

2. Maybe oil is leaking into exhaust over night and being burnt up on cold starts gone by the time vehicle is warm????? Long shot.

3. Maybe vaccum leak or boost leak somewhere.

4. Maybe to much sludge in the intercooler restrictting some of the flow if that even makes a difference to the way the car runs.



Over all yes I agree this problem happened fast and should be an easy fix if we can just track what it is that is causing it maybe faulty sensor whiklst cold leading to over fuelling???
Author:  kelticknight [ Tue Aug 11, 2009 5:37 am ]
Post subject: 
a friend of mine who has a garage couldnt figure it out and got a vw mechanic who got a rep for being good,he just comes and does it ,no questions,had injectors done before by someone else and they did poor job as they didnt seat probly and the vw guy came did the job no one else wanted too do,after he did the injectors ,he put jeep on a laptop which has the software to check setting for jeep,was told everything was work as irt should according to readings,he checked air flow,fuel system,because of waht he did,smoke is better but still there,i have samco hoses and wondering idf i should put bback old hoses,still wondering if i should replace injectors for new ones,
Author:  damo4runner [ Tue Aug 11, 2009 6:26 pm ]
Post subject: 
No I have the factory hoses and no difference in smoke although I need to replace as the air box has just about rubbed though the factory ones, just reset car this morning andwillsee how things go today on a drive. By chance did you start having extra smoke problems after being in mud or muddy water the sloppy stuff that you have to get under the car to clean off.
Author:  kelticknight [ Tue Aug 11, 2009 7:34 pm ]
Post subject: 
underside of jepp is very clean i was told by grease monkey,just think theres something simple im missing causing it,will figure it out
Author:  kelticknight [ Tue Aug 11, 2009 7:50 pm ]
Post subject: 
underside of jepp is very clean i was told by grease monkey,just think theres something simple im missing causing it,will figure it out
Author:  damo4runner [ Wed Aug 12, 2009 12:17 am ]
Post subject: 
OK I reset ecm or ecu whatever it is called basicly unplugged battery for 1/2 an hour and then reconnected it and cold start idle for 15 minutes seemed better on drive no real smoke diffeniately no where near what it is after I leave work in the arvo but I don't work again till 2morrow so that will have to wait till then. On the other side of things mine NORMALLY only smokes bad when cold until warmed up and then it seems acceptable so my other thoughts were maybe the penrite hpr 10-40w oil is to thin at cold start or maybe I have a faulty boost/air temp sensor do you take yours out to clen it and do you use thinner oil (synthetic is what the penrite stuff is) Smoke has from memory been there since I started using it can't quite remember if it was there before hand
Author:  kelticknight [ Wed Aug 12, 2009 6:44 am ]
Post subject: 
i been using semi synthetic for long time,when mine is cold,its about the same when warm,will unplug battery and reconnect at weekend to see if it makes any difference,i take out the sensor on top of engine which get soot build up some times,i dont touch rest of sensors,some thing to look into also
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