TD5 Running Problem

Stuarts the man · May 1, 2009

Hi Guys
prob;em with mates 2003 td5, starts first time off key purrs sweet as a nut, try to bring revs up but will not rev over 2500-3000rpm stutters all the way, grey/black smoke from back,
Fuel fine, changed fuel filter, checked turbo hoses for delaminating they are also fine, air filter ok. diagnostics show no faults
Any help would be appreciated

bluerazor · May 2, 2009

Hi Not sure about the Grey/black smoke "could be the Turbo packed in"
But the stutter effect i once had on my TD5 and it was the wastegate stuck
I put some WD40 to get the lever movin then some high temerature oil so it doesn't
dry up quickly.
Good luck
Vince

Headtester · May 2, 2009

Stuarts the man said:
Hi Guys
prob;em with mates 2003 td5, starts first time off key purrs sweet as a nut, try to bring revs up but will not rev over 2500-3000rpm stutters all the way, grey/black smoke from back,
Fuel fine, changed fuel filter, checked turbo hoses for delaminating they are also fine, air filter ok. diagnostics show no faults
Any help would be appreciated

Have you checked the injector wiring loom ?

Beast o Bodmin · May 2, 2009

you could get a tdi....

Stuarts the man · May 2, 2009

pulled ecu out today, injector loom and plugs fine

Stuarts the man · May 2, 2009

i could get a tdi but i dont want to be welding it every week

bluerazor · May 2, 2009

Had A similar fault on mine but with no Grey /black smoke
Turned out to be the wastegate lever on the Turbo Stuck.
I sprayed some WD40 then high temperature oil now it's working much smooth.

ratty · May 2, 2009

bluerazor said:
Had A similar fault on mine but with no Grey /black smoke
Turned out to be the wastegate lever on the Turbo Stuck.
I sprayed some WD40 then high temperature oil now it's working much smooth.

If the turbo wastegate is sticking it should only do it under load.

My money is on the egr valve.

bluerazor · May 3, 2009

Stuart didn't state if it's under load or just idle?

Stuarts the man · May 7, 2009

at idle smooth, only once revs come up do you get this problem, which makes it undriveable, wastegate working fine, egr valve bypassed, still the same, running out of ideas here

ratty · May 7, 2009

Stuarts the man said:
at idle smooth, only once revs come up do you get this problem, which makes it undriveable, wastegate working fine, egr valve bypassed, still the same, running out of ideas here

I would re-check your turbo hoses. Black smoke is overfuelling.

When you say it's been on a diagnostic and there are no codes showing, Was the vehicle driven around with the diagnostic plugged in? What were the MAF, MAP and throttle pedal values? All of these can cause the loss of power, The MAF is the most common to fail but doesn't usually result in smoke.

The fault showing a code on the diagnostic should be crossreferenced with the results of the live data stream in order to get an accurate picture of whats happening. If no fault code is given, The live data can often hint at what the problem is by the values shown.

Just outta curiosity, Is there any strange burning or eggy smells? Is there an unusual rattle from the underside of the vehicle? Jut wondering if the cat is fecked. Try hovering your hand over the end of the exhaust while the engine is revved. Are there any sparks or does your hand feel prickly?

CharlesY · May 7, 2009

STart to suspect copper washers under the injectors leaking when the load comes on and the pressure goes up.

If you were VERY LUCKY .... this might help

you take the lid off the engine, and TORQUE DOWN the injectors again.

RAVE says ...

17. Carefully fit EUI’s, ensuring they are in their correct fitted order and that the retainer is
located on its dowel. Tighten Torx bolts to 32 Nm (24 lbf.ft).

When tightening down, first UNDO the Torx Bolts about an EIGHTH of a turn (NO MORE!) and then torque UP to a bit MORE than 32 Nm (24 lbf.ft) - say 36Nm - VERY SLOWLY.

This is an easy DIY job, but you do need to be careful re-fitting the cam cover (the lid) as the rubber gasket flops about at the back, and needs a poke with a bit of welding wire (special Tool LZ 000001 ) to help it into place.

If this fixes it, great.

If it makes ANY improvement buy and fit a full set of copper washers and O-rings.

I had to do mine at under 20k miles still in warranty. There was NO WAY the local main stealer's drug crazed cretins - sorry, "automobile technicians" ... were touching MY car.

CharlesY

disco_steve · May 10, 2009

Have you checked out the air mass meter unit ?

Failing that, could be injector(s) ?

Mine had a miss fire like splutter, which turned out to be teh injector loom, for the sake of £35 ish quid, may be worth changing anyway - dunno other than that !!

Stuarts the man · May 12, 2009

problem fixed
vacum unit at back of drivers side inner wing, where egr vacum pipes go into was blocked, changed it and now fine
Thanks for all your help, hopefully this may help someone else with same problem

CharlesY · May 12, 2009

Stuarts the man said:
problem fixed
vacum unit at back of drivers side inner wing, where egr vacum pipes go into was blocked, changed it and now fine
Thanks for all your help, hopefully this may help someone else with same problem

WHAT ?????

You mean the EGR stuff is still attached to the engine?????

OH NO !!!!

CharlesY

Stuarts the man · May 12, 2009

not any longer bells bypass kit fitted, thats how i found out problem

Dave 2000 · May 13, 2009

Stuarts the man said:
i could get a tdi but i dont want to be welding it every week

Get a spanish one if you don't mind LHD, very little rot here.

regards

Dave

ratty · May 13, 2009

Stuarts the man said:
not any longer bells bypass kit fitted, thats how i found out problem

Hang on minute. I said...

ratty said:
If the turbo wastegate is sticking it should only do it under load.

My money is on the egr valve.

you replied with....

Stuarts the man said:
at idle smooth, only once revs come up do you get this problem, which makes it undriveable, wastegate working fine, egr valve bypassed, still the same, running out of ideas here

then you said.......

Stuarts the man said:
problem fixed
vacum unit at back of drivers side inner wing, where egr vacum pipes go into was blocked, changed it and now fine
Thanks for all your help, hopefully this may help someone else with same problem

To which CharlesY replied with......

CharlesY said:
WHAT ?????

You mean the EGR stuff is still attached to the engine?????

OH NO !!!!

CharlesY

You then replied with....

Stuarts the man said:
not any longer bells bypass kit fitted, thats how i found out problem

If you've only just found the fault when you fitted the egr bypass, How was it fitted before?

CharlesY · May 13, 2009

ratty said:
Hang on minute. I said...

you replied with....

then you said.......

To which CharlesY replied with......

You then replied with....

If you've only just found the fault when you fitted the egr bypass, How was it fitted before?

Ratty,

Did you ever think of taking up a position with the Inquisition?

Good question. I was flummoxed by the somewhat confusing statements as to his EGR situation.

CharlesY

ratty · May 13, 2009

CharlesY said:
Ratty,

Did you ever think of taking up a position with the Inquisition?

Good question. I was flummoxed by the somewhat confusing statements as to his EGR situation.

CharlesY

I thought about joining em but they said I was too soft on noobies.

It was the statement that it was already bypassed that got me. Most people ask what the hell an EGR is when it is quoted as being a possible suspect. The fact he answered that it had been bypassed showed that he had knowledge of it's presence.

I can only assume that he was under the impression that by simply pulling off a vaccuum pipe or a wire would bypass it.

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