BKD Turbo Removal

[kevster996]

The VW specialist did a VCDS scan and it just comes up with overboost code and too much airflow so it pumps in diesel to match and overfuels the engine hence the black smoke when revving. They said everything else tested ok, vacuum pipes etc.

I thought it could be a blocked cat (with all the lost water going through the engine when the EGR cooler went) so Ive replaced that now and its exactly the same - limp mode on hills.

Ive ordered a boost pressure sensor as thats pretty cheap and about the only thing I havent changed. Its got a new bosch MAF on but maybe thats faulty giving false air flow? If it was then disconnecting would be a good test I think as it would use a default value and then not overboost?

About £700 spent now on parts and still got the issue...

I dont think the intercooler or pipework could cause the overboost problem  - pipes dont seem to have any splits in them. I did blow a few joints but thats because I didnt locate the spring clips properly - Ive screwed them together now so theyre secure...

[kevster996]

Just had it back in for diagnostics with the new boost pressure sensor fitted and they cant figure out why its overboosting still. They are suggesting possibly swap over the ECU and maybe put the EGR back on with the cooler. I have all the old bits but the EGR cooler is toast I would have to get another 2nd hand one of those.

So possibly a cheap ECU (problem with immobiliser?) and EGR cooler... They also suggested to get it on a rolling road to map it to see exactly where the problem is kicking in. Still overboosting on hills but also too much air flow reading so its pumping in too much fuel and hgetying balck smokoe ou thte back when revving it parked up...

Im fed up spending more money on it to fix it but need to get it roadworthy again :(