1.9td lacking power

[chrisuk]

i've just picked up a seat cordoba with an aaz 1.9td motor in it - bought it cheap with what initially suspected was a turbo fault - basically there is no power above about 2200rpm. it will rev higher, but won't pull above this point. Theres no audiable noise from the turbo above then engine noise, though i can hear a whistle at higher revs through the housing using a screwdriver to listen. The impellor on the compressor seems to spin freely enough (havent taken exhaust manifold off yet to check turbine). Its not smoking, using oil or making any funny noises, just severely lacking power. It only has 46k miles  on the clock and has full stamped service book. any ideas before i start whipping everything to pieces or buying replacement turbos? cheers!!

[RedRotors]

Check the WG, perhaps it's stuck open.. If the rod can't move with your hand, you got a problem..You can also check the hoses going to the WG actuator for leak.. It could be a good start..

Marc/

[QuickTD]

If the wastegate has 2 hoses on it, pull off the smaller of the 2, plug it, and go for a drive. Some of these engines had a wastegate "opening" system that worked in conjunction with the EGR. The wastegate is pulled open by vacuum while the EGR is in operation. Some models that were not equipped with EGR still had this system in place. If the system is malfunctioning it will not allow the wastegate to close.

[Wingaman]

If you have this kind of switch on your fuel pump :



Remove the screw #1 and #2 and leave it open somewhere on the engine. It can be this switch who leave the wastegate open.

The complete document where the pics whas get is :

[chrisuk]

Cheers for the help people. theres only one small hose on the actuator that i can see, leading over the top of the compressor housing. I'm new to turbos so please excuse my ignorance, but is the rod mentioned the threaded rod leading out of the centre of the actuator? Will try the above suggestions and see how it goes

[chrisuk]

Had another look this evening - i don't have that switch on the top of the diesel pump. I bought a boost gauge and hooked it up to a t-piece on the hose between the pump and the inlet manifold though - i don't get any boost below 2k revs but it is showing about 0.6bar at 3-4k revs so it does seem to be boosting. just got no "go"

[RedRotors]

Had another look this evening - i don't have that switch on the top of the diesel pump. I bought a boost gauge and hooked it up to a t-piece on the hose between the pump and the inlet manifold though - i don't get any boost below 2k revs but it is showing about 0.6bar at 3-4k revs so it does seem to be boosting. just got no "go"

0.6 bar with no load on the engine?

Marc/

[chrisuk]

no that was driving the car 2nd and 3rd gear under load

[chrissev]

i've just picked up a seat cordoba with an aaz 1.9td motor in it - bought it cheap with what initially suspected was a turbo fault - basically there is no power above about 2200rpm. it will rev higher, but won't pull above this point. Theres no audiable noise from the turbo above then engine noise, though i can hear a whistle at higher revs through the housing using a screwdriver to listen. The impellor on the compressor seems to spin freely enough (havent taken exhaust manifold off yet to check turbine). Its not smoking, using oil or making any funny noises, just severely lacking power. It only has 46k miles  on the clock and has full stamped service book. any ideas before i start whipping everything to pieces or buying replacement turbos? cheers!!

This might seem obvious but did you check for obstructions in the fuel delivery area like clogged filter, pinched fuel hose, bent metal lines from someone jacking the car from underneath, that sort of thing?  Happened to me with a diesel rabbit once that the garage lifted the car on the fuel line and crushed it.  No power at all after that (because the engine couldn't get enough diesel).

[chrisuk]

Just ordered a new fuel filter, and will check all hoses this evening for splits/kinks/leaks.
i've just seen this (http://vwdiesel.net/phpBB/viewtopic.php?t=488) post - this is the same setup as mine - if its permanently boosting what sort of revs should i be seeing pressure from, and what sort of pressure should it be showing?

[chrisuk]

problem solved! someone had turned the max rev limiting screw waaay too far (5 turns too far in!!), so the throttle arm was only moving about 1/3 of the distance it should have been, with the spring-loaded arm taking up the rest of the movement! So the "cheap" car with a fault that I bought off a dealer has turned out to be perfectly fine, and a real bargain!! Thanks for the suggestions and advice though folks.

Its my first TD, and coming from an 8v gti jetta I was a bit concerned that it might seem a bit sluggish, but must say I was really impressed!! It pulls from nothing, and revs really willingly. So add a new very happy very impressed TD owner to the ranks, people!!