At wits end

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having read your saga of the faults, initially i was thinking its a turbo problem (sticking vane control,/solenoid is common) and injectors,

what i would check now is the map sensor, it detects the air pressure in the plenum chamber, it is located left hand side on the air chamber, remove and clean it with a spirit based cleaner,
 
Thank you for the help!

I will clean the map sensor tonight and let you know.

Diags are clear. Turbo Boost is 1Bar they want to push it up to 1.2 bar this I think may be a bit high. any ideas?

The EGR is disconnected or connected no change. However I will try and see if it is sealing properly. Blank the thing off.

Does anyone know where would be the best point to attach the match :frusty:

Will post tomorrow again

BTW having read of the dirt in the system on some other forums mine is quite clean.
 
???? Is the MAP sensor the same as the boost pressure sensor?
The process of making the diesel engine run isn't complicated. The induction stroke pulls in a gut full of air and then at the ignition stroke fuel is injected into this air at very high pressure.

On older diesels the turbo effectively increased the displacement of the cylinders by introducing more air into the system at higher than atmospheric pressure. Add more fuel to this extra air and you've got a bigger bang, so more power.

In modern diesels the turbos role has changed. The green lobby don't like over fueling as this leads to nasties in the exhaust so the turbos role is to always ensure there is more than enough air for the fuel load that is injected to burn completely.

So in the TD4 design the turbo actively adapts to prove useful boost from idle speed upwards. This means plenty of capture of these exhaust gases to keep the turbine speed high enough to have an effect. However, when the revs are up and the power is really on then this arrangement will cause an overboost. Therefore an actuator operates vanes which steer the exhaust gases off the turbine blades to reduce the turbine speed and limit the boost pressure level. The turbos job is to make the engibne burn clean rather than for outright performance.

This change in design is clearly seen by the fact that the boost pressure is so low. Where the TD4 operates at 1 bar, the L series operates at 1.7 bar. Howver, without the turbo the L series will still run at low power levels. I had to limp home with a blown induction hose fitting. There was no boost at all and the engine was running effectively naturally asperated. It ran but I could do little more than about 40 MPH.

The Manifold absolute pressure sensor relays the air pressure that is entering the cylinders back to the ECU. This information will be used to determine 'Green' fueling levels. The Turbo boost sensor will monitor the pressure at the turbo discharge port and is more likely to control the boost limiting vane position. Between these two is the intercooler which will effect a pressure difference between the two sensors. Again the L series only has the boost sensor so to be able to determine the additional fueling demand as the turbo spools up.

If you are experiencing misfire then the fuel system is the only place to be. Either the ECU is miscalculating injection timing because of duff asperation data, which seems unlikely after all this work, or the injector are opening but there is too low a fuel pressure behind them to cause a good enough spray pattern or deliver enough fuel.

By all means elliminate the MAF sensor, my money is still on the fuel pumps myself.

Good luck.
 
Hi Thank you for all the suggestions.

This is a TD4. No pump in the tank

An important point is that it pulls well in cold weather but very sluggish when the day has warmed up and the power loss is noticed on the bottom end of the throtle curve at pull away and slightly when under load going uphill.

I did not get around to the MAP/boost presure sensor on the intake manifold but will attend to that tonight.

Regards

Brian
 
Errr, are you sure about that? The TD4 upto 2003 did have a tank mounted pump. I maybe wrong but I can't see how a common rail system can work without a tank side pump.
 
Right Darmain, If there is an underbonnet LP pump then there is also one in the tank.
 
Hi Thank you for all the suggestions.

This is a TD4. No pump in the tank

An important point is that it pulls well in cold weather but very sluggish when the day has warmed up and the power loss is noticed on the bottom end of the throtle curve at pull away and slightly when under load going uphill.

I did not get around to the MAP/boost presure sensor on the intake manifold but will attend to that tonight.

Regards

Brian
my old and very wise spanner monkey once told me there was a temp sender for my fuel system on a td engine seprate to the sender for the dash i dont know if this is true on a td4 but if so might explain a lot aparently it worked like a choke on an old petrol engine so enriched the mix when cold and then reduced mix when warm so if im rite may go some way to explain your problem
 
OK

No pump in tank it is mounted in the rear wheel arch in the SA models.
Since last post

Removed MAP sensor and cleaned it, no change.

Returned the car to the Turbo people on Monday. They have:-
1) Confirmed that it is not pulling right so they jerked the turbo out again still boosts 1.1 bar.
2) Checked all the sensors again
3) Diagnostics gives a fault to do with the emission control only after a while
4) They replaced the EGR again as well
5) The fuel pump boosts 4.5bar so they are happy with that?

They have now asked to leave the car with them a while longer. They are sure it is a small problem that they have not yet been able to locate such as a lose wire in the loom.


Regards

Brian
 
We had the same problem as this on a tractor at work and it turned out the fuel pump was knackered.

I presume the fuel and air filters have been changed? There might even be a little glass globe on the engine somewhere, is this clean?
 
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