smoke

[mk1vdub]

how much smoke do all you guys who've done some mods produce?

I have a 1.6 GTD engine with k14 turbo in my mk1, it has a green cone filter, 2 1/4" down pipe mating up to the old crap tiny exhaust (on the to do list) and I'm running a fairly large front mounted intercooler - see pic:



I am running around 1.2 bar, I have done the govenor mod - solidified the intermediate spring and ever so slightly pe loaded the main, and have also adjusted the rotation and depth of travel of the boost pin in the lda

I first pretty much went for max adjustement on pin rotation and a bit more depth which was great, I noticed a big difference in power, but it smoked alot, I have been backing off the adjustments gradually in an effort to reduce somking but I'm not that far from the factory positions now and still smoke a fair bit...

I've read of people saying they're running shed loads of fuelling and still don't smoke but I can't beleive this

so - what sort of mods have you done and how much smoke do you get?

[935racer]

Hey thats a real nice intercooler, what is it from? I think your little k14 turbo is oging to be one of your smoke issues, at 1.2 bar you are starting to pump hot air back into your engine all though that large intercooler will help tremendously. Try upgrading to the garret t3 or kkk k24 turbo, I have runs lots up to 35psi wih no reliability issues, but with that IC and 25 psi on one of the stock 1.6 turbos you should eliminate your smoke. The biggest restriction in these motors is the crappy heads and ports and intake manifolds. Malone here ont he forum had a pump built by giles, that smoked an unbelievable amount on the stock 1.6 head and manifold, like you would swear his car was gonna blow there was so much smoke and the egts were out the roof. He than toasted the motor and I gave it a full rebuild and got a 1.9 TD head and ported the crap out of it and modified the deck of the head to flow as much air as possible, I also installed a PD130 intake manifold. Now with no intercooler and 30 psi there is no smoke. It was crazy when we got it running we were like WTF where is all the smoke? I had to turn the fuel screw in a couple turns and back the idle screw all the way out before we even had a haze. When I called giles to tell him we needed way more fuel, like way more he didn't believe me at first. Holy smoke so taht was a big rant but to sum it up get a bigger turbo and look into porting or fitting a 1.9 head on and think about getting a bigger intake as well. Also maybe address the IC plumbing... it looks like it had been duct taped???

[3beejay3]

Also maybe address the IC plumbing... it looks like it had been duct taped???

I was going to say - what's with the 'Red Green' Intercooler installation?

BJ

[WishIHadaRabit]

I have a theory.
I installed an intercooler & an oil cooler, and my car slowly started smoking more and more.
I think that with the cooler engine temps and cold air, complete combustion is not occuring.

My solution:
This week, I'll try advancing pump timing or cam timing or both. I'll let you know.

[Black Smokin' Diesel]

Holy macarony that's a big intercooler!!! Duct tape, the handyman's secret weapon!

[jtanguay]

Yea colder temps definitely lead to improper combustion.  If only we could keep the temp sealed in the chamber we would be laughing!

[935racer]

Actually a properly instaleld intercooler SIGNIFIGANTLY decreases smoke, cold air burns better, giving a more complete combustion. If you believe that the fault is in your intercooler than it must be clogged/blocked somewhere, something is not right. I installed a big FMIC on a customers car recently that was smoking like crazy, after the install, no smoke. A few days later he complains to me that the FMIC makes his car smoke like crazy at start up and it almost doesn't start at all, so he brings it back, turns out the tool took off his inner fender (which is where his  K&N sits) and than drove through a bunch of puddles and construction zones and completely clogged his air filter. I took it off and thouroughly cleaned it and it has been running like a top ever since.

[935racer]

Yes colder air does burn better. I do some backcountry snowboarding/camping and the propane stoves we use have a blue and yellow flame down at sea level, but when we are up in the mountains at 2000+ meters you can't even see the flame, it is totally clear. This is why everyone loves driving their performance cars in cold weather, especially us turbo and or diesel guys. We can add more fuel :twisted:

[WishIHadaRabit]

Yesterday I decided to bypass my oil cooler and intercooler

here's what happened:
- Head temperature went from 225 degrees to 240
- Engine sounds better (less chatter)
- NO more smoke
- a slight drop in power under full boost (nothing noticeable under normal driving conditions)

Next on my to-do list is hocking that stuff back up and advancing the timing

[935racer]

Hmmm interesting, I wonder if it could be your oil cooler. Maybe the oil cooler is somehow buring oil??? What kind of oil cooler are you using? How is it plumbed? The increase of head temps and decrease in power make me think your IC is functioning but the decrease in smoke doesn't make much sense. Can  you verify the smoke is unburnt fuel (black) and not oil (blue)?

[mk1vdub]

ah excellent thanks for the replys guys I ment to respond sooner but kept forgetting!

935racer - thanks for a great, helpfull reply,

the intercooler is from a landrover td5 I basically just bought the bigest one with roughly the right dimensions to fit in the space!  it did take a bit of fettling to get it in I've no idea how efficient it is or anything either..?

yes in the pic it is gaffa tape round the boost pipes   it was basically ment to be a temporary thing to mock up pipes, which are pvc plumbing pipe all round, but I just left it there while running in

Duct tape, the handyman's secret weapon!

 yep exactly - proper ghetto :lol:

unfortuanetly I did find that it couldn't really hold 0.7 bar with the under bonnet temps and there was me thinking it could do basically anything!

after it was run in, I'd left all the pipe work as it is beacuse I'm lazy like that, and I started to make full boost ( still factory 0.7 bar at this stage) it started popping tape off and pipes out of connector all over the place, so everytime that happened i strengthened each joint. the pvc is now all solvent welded with proper rubber hose and juibilee clips in places and has been holding up very well with 1.2 bar

anyway back on track - its good to know that the k14 is on the edge of its efficiency range so essentially I just need a bigger/better turbo and more air I will be keeping an eye out for a k24 or t3 and will look into a 1.9 head and better manifold etc!.  

[Op-Ivy]

Thats what I love about our cars! The smoke! It gives a car character. Too bad its cold up here now and I cant spit anything for black stuff anymore

[Rat407]

How much modification does it take to put a 1.9 head on our 1.6 TD's?

[DVST8R]

How much modification does it take to put a 1.9 head on our 1.6 TD's?

If its a hyd lifter head, its just a matter of putting it on.

[935racer]

He means if its a hyd BLOCK its a bolt on :wink:  You will want a 1.9 intake manifold as well, your 1.6 is too tiny.