2005 TD4 smoking and no power

Hello

I have a 2005 TD4 which is producing a fair amount of black smoke and very little power, plus an intermittent engine management light (no code stored), normally at motorway speeds.

So far I have checked EGR, checked for vacuum leaks, already had a fuel pump and filter, replaced the boost solenoid and can see the boost control valve moving fairly well from the wheel arch..

I have checked the intercooler hoses and cannot see any holes or splits...

My next step is turbo out to check...

Anyone have any additional ideas before I do that?

Thanks

You could try unplugging the MAF and see if that makes any difference

Are you sure you don't have a boost pipe split. The elbow pipe to the EGR valve it the favourite for that.
Or you have a sticking EGR valve.
As there's been a MIL event, there will be a code stored. An 05 is OBD2 compliant, so any generic reader should give you the fault code.

I've known a cheapo code reader to tell me there are no codes when there are. What reader do you have?

I have also removed the vacuum from the EGR just in case...

A friend plugged in a solus machine which showed old errors, including the boost solenoid (which has been changed), but no new codes are being stored.. and the live data all seems OK... things like expected and actual fuel pressure etc...

Staggan said:

I have also removed the vacuum from the EGR just in case...

A friend plugged in a solus machine which showed old errors, including the boost solenoid (which has been changed), but no new codes are being stored.. and the live data all seems OK... things like expected and actual fuel pressure etc...

Click to expand...

Before pulling the turbo out I would read the boost pressure. Also suspicious of MAF and a hidden boost leak.

Perhaps a few screenshots of readings at idle, 1000 and 2000 rpm?

Unfortunately I don't have access to the solus now...

As for boost leak... I tried spraying soapy liquid around hoses and joints to check... and as a second try I used carb cleaner.. no change in engine note at all...

I am loathed to try yet another replacement MAF as well... it has had at least 3 whilst trying to resolve this issue.....

Have you checked and cleaned the EGR valve. Or blanked it off at the exhaust connection?

Staggan said:

Unfortunately I don't have access to the solus now...

As for boost leak... I tried spraying soapy liquid around hoses and joints to check... and as a second try I used carb cleaner.. no change in engine note at all...

I am loathed to try yet another replacement MAF as well... it has had at least 3 whilst trying to resolve this issue.....

Click to expand...

I wouldn't say spraying stuff is the best test for a boost leak. The last two I had would not have been detectable that way - a slit in the hose that only opened on boost. More useful in a petrol engine where there's vacuum.

Might be an injector clogged. Had simler lack of power and found one injector was stuffed up with sutt, no mil light though. Easy test at tick over, just pull a lead one at a time and note engine change. Mine must ave been runin on 3 for months

if you are still driving it block up that vacuum pipe or you will have trouble breaking.

Injectors were all tested and fine.. EGR is disconnected and the vacuum hose sealed..

I have had the intercooler hoses off and see no signs of splits or holes.. and with the engine running I put my hand over each of the hoses which pressurised.. and no hissing or apparent leaks..

I am still leaning towards faulty turbo.... perhaps bearings are gone and it is not spinning up properly? Actuator seems to move plenty suggesting vanes are not stuck...

If the turbo wasn't spinning up, the hoses wouldn't go hard. They would tend to suck in slightly, as the engine air demand increases. So the turbo is boosting OK. Have you checked to make sure the EGR valve is solidly closed. I've seen one where the spring failed. This allowed exhaust gas to enter the inlet unchecked.

You could do with looking at the live boost data. Also is the inlet manifold clear of black gunk and the MAP sensor port clear?

Actually boost seems less than on my dads one... his hoses get much harder than mine (sounds very bad)

EGR seems to be closed fine... I could get a blanking kit I guess..

I cleaned the inlet manifold and the MAP sensor etc.. but could check again as it was a while ago...

I'll also see if I can borrow the solus again... since none of the bluetooth adapters I have seem to connect with it...

A 2005 is OBD2 compliant. So an elm327 Bluetooth dongle hooked up to droid app Torque will give you all you need to know.

I have both... and I get constant errors trying to connect.. Although I don't think it is a real elm327... think it is a compatible...

Staggan said:

I have both... and I get constant errors trying to connect.. Although I don't think it is a real elm327... think it is a compatible...

Click to expand...

Compatibles are an issue sometimes. I have a compatible and it's fine. It's the luck of the draw with them.
Make sure the OBD2 port contacts are closing on the elm pins. Sometimes the pins are a bit narrow and don't contact correctly.

So... tried removing turbo today to check it....

On the intake / compressor side from the air box, should there be a jubilee clip or something holding that pipe onto the turbo? Mine has nothing..

Also, getting the bolts out of the top through the airbox.. really struggling with getting a 13mm socket on.... body of my sockets all seem to thick... any suggestions?

Thanks

I've just read something else that says those 3 bolts are torx.. is that true? Could explain a lot..

5mm Allan key if you're talking about the air filter cover.