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VW Golf 1.9 TDi BKC 2005 - Inter cooler hose collapses - Fixed #

Posted by Ian Gray on March 24, 2011, 3:55 pm

Year of Manufacture *: 1995
Engine Size and Code *: 1.9 BKC
( Optional) Fault Codes: None

Hi all, we have this Golf in at the moment, Total lack of power & when revved the top intercooler hose which attaches to throttle valve completely collapses. We've checked for blocked hoses, intercooler, air filter etc. Turbo seems OK & spins freely by hand. When revved really hard there are also exhaust gases coming back through the air cleaner. Have tried blanking of EGR valve but still no different. It's almost as if the turbo is running in reverse (not possible I know)
Just wondered if anyone has come up against anything similar, any help would be greatly appreciated.
Thanks, Ian

Re: VW Golf Tdi - Intercooler hose collapses

Posted by Phil Huelin <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3254' width='330' height='300' border=0 style='border:none;'> on March 24, 2011, 7:40 pm, in reply to "VW Golf Tdi - Intercooler hose collapses"
Phil Huelin

Had one with that 'throttle valve' staying shut causing your symptoms. I think it was gumming shut with carbon. Carb. cleaner and toothbrush! If hoses are collapsing there must be something closed that oughtn't to be?
Kind regards
Phil

Re: VW Golf Tdi - Intercooler hose collapses

Posted by Ian Gray <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1648' width='330' height='300' border=0 style='border:none;'> on March 24, 2011, 7:48 pm, in reply to "Re: VW Golf Tdi - Intercooler hose collapses"
Ian Gray

Thanks Phil, will take another look tommorrow.
Bit of an update - if we run it with the outlet/pressure hose disconnected at the turbo the inlet hose does not collapse, obviously no boost.
Cheers, Ian

Re: VW Golf Tdi - Intercooler hose collapses

Posted by keith geach <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5403' width='330' height='300' border=0 style='border:none;'> on March 25, 2011, 8:16 am, in reply to "Re: VW Golf Tdi - Intercooler hose collapses"

Phil
Year 1995
Engine code BKC, they didn,t fit a PD engine in this model (or have one in general production)

1Z or AHU?

Is this a special?

Re: VW Golf Tdi - Intercooler hose collapses

Posted by Ian Gray <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1648' width='330' height='300' border=0 style='border:none;'> on March 25, 2011, 11:24 am, in reply to "Re: VW Golf Tdi - Intercooler hose collapses"
Ian Gray

Sorry - Year is 2005

Fixed #

Posted by Ian Gray on March 25, 2011, 9:18 pm, in reply to "2005 VW Golf Tdi - Intercooler hose collapses "
Message modified by board administrator March 26, 2011, 1:21 pm

Turned out to be a sheared impeller shaft. Output rotor spun freely with no free-play. Exhaust rotor sitting in end of turbo.
Why are these VAG turbo's so rubbish ??????

Re: 2005 VW Golf Tdi - Intercooler hose collapses - Fixed

Posted by keith geach <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5403' width='330' height='300' border=0 style='border:none;'> on March 26, 2011, 7:21 am, in reply to "Re: 2005 VW Golf Tdi - Intercooler hose collapses - Fixed"
Keith Geach

The way to find this is to remove outlet pipe from turbo and listen, you will know how a good one sounds and how a broken one sounds, you can also look at compressor wheel and will see the speed will not look correct.

With millions of turbos out there how many actually fail?

So then is this down to poor servicing (oil, filter etc) to long between services or the control system not working correctly on the turbo and this being ignored?

Re: 2005 VW Golf Tdi - Intercooler hose collapses - Fixed

Posted by lee woods <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3096' width='330' height='300' border=0 style='border:none;'> on March 26, 2011, 3:40 pm, in reply to "Re: 2005 VW Golf Tdi - Intercooler hose collapses - Fixed"

Hello Keith , quite a few of these turbos still fail when they have had regular services and good oil ect.

Could it be a design trate ...the way the gases are directed to the impellar, or could it be that the turbo is made to work harder at lower engine rpms.....its always spinning its fastest even with low engine speeds.

I am not sure ? just some ideas

Re: 2005 VW Golf Tdi - Intercooler hose collapses - Fixed

Posted by Ian Gray <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1648' width='330' height='300' border=0 style='border:none;'> on March 28, 2011, 5:12 pm, in reply to "Re: 2005 VW Golf Tdi - Intercooler hose collapses - Fixed"
Ian Gray

Hi Keith, this one wasn't making any strange noises (probably because the shaft had sheared & the exhaust turbine wasn't spinning) We've also seviced this car from new, always with genuine filters & correct oil and at the correct intervals. We've changed many T5 turbo's that have suffered the usual clouds of smoke & grinding noises which as you say, you can tell how a good one or bad one sounds. Should have investigated further before posting I know. Thanks for your advice though.
Cheers, Ian.

Re: 2005 VW Golf Tdi - Intercooler hose collapses - Fixed

Posted by keith geach <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5403' width='330' height='300' border=0 style='border:none;'> on March 28, 2011, 5:59 pm, in reply to "Re: 2005 VW Golf Tdi - Intercooler hose collapses - Fixed"
Keith Geach

Ian
The lack of noise is what to listen for at idle it will be in full boost position and with the pipe off you can hear this, try it with a good unit and you will know what to listen for, (put it in and out of boost with mityvac or basic setting)

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