TD5 very rough running and black smoke

Hi all,
starting from the beginning,
the morning following a faultless long journey I start My 2004 15P TD5, its starts instantly but is hunting and knocking. after checking various connections (ECU for oil etc) I changed the fuel filter to no avail.
I took it to a garage thinking they could get it fixed quicker than my self and they've run a nano com to find a fault with all injectors, after clearing it and running again only 2 faulty injectors are shown.
they've sent all injectors off for testing and have come back good, so when reinstalling they renewed injector copper washers, o-rings and loom only to find it still running poorly.

anyone got any ideas??

thank you very much,
Callum

does black smoke not signify possible intercooler or air pipes delaminating near the turbo?

that's what i thought but apparently the garage have checked for that and it's all ok.
many thanks
callum

sounds similar although mine is rough through the entire rev range, I believe they've checked/changed most of the sensors. I will raise some of the points raised in that post.
many thanks.
Callum

Speak to Alive tuning, they are regarded as the best in the world for the TD5.
If they are good enough for BMW racing to use then they are good enough for me.
Nanocom is ok but all it can do is replace the map file, it cannot really edit it.
Dont get me wrong Nanocom is a great little gadget for diagnostics but i would not really use it to re map an ecu.

If I remember right the TD5 software is 4 files*
1 Firmware
2 Fuel Map
3 Vehicle ID and info
4 Redundant

See link below its not as simple as just finding the file on the web and uploading.
Nanocom cannot do the stuff you see below.

http://www.discotd5.com

I guess after the first 4 or so subjects in the link you will be thinking, "i am getting the feeling i need to send my ECU to an expert" ;-)
just one thing not right can cause load sof 'false' symptoms that will lead you down all sorts of dead ends!

Just send it to Alive tuning for testing and software / fuel map update.

http://www.alivetuning.com/product/td5-ecu-remapping/

You pays your money, you takes your choice,

My 2003 def 90 TD5 has been running better than it ever has before, i wish i had done it sooner after wasting money replacing loads of perfectly good parts and many many hours and lots of swearing!

good luck mate!

thank you,
I found someone from alive tuning on a defender group, I've sent him a message.
i beginning to think it is electrical or a sensor, because its been so sudden and all cylinders are affected (from what it sounds like).
My next idea is to find someone local with a spare ECU and plug it in, is this fairly straightforward?

many thanks,
Callum

http://www.discotd5.com/node?page=1

fuel density, WTF? I just don't have the time or energy to learn this stuff, (AKA cannot be arsed)
seems like my school reprots were right all along....
"highly intelligent, but lakes the motivation to see things through, gets bored easily, could do far better if he could focus on the task in hand"
About then i discovered girls, and music that was that!

thats what I thought!.

1) was caused by too many nanocoms and amateurs connecting to the ecu trying to read stuff with crappy diagnostic machines. ( I have a delphi diag system now)
2) borrowing an ecu is not that simple, if you can find someone with the year, same engine, same fuel map and the right version for your exact engine crack on!

this was just my experience, may not be the same for you, but having gone through the madness

read here:
https://www.landyzone.co.uk/land-ro...-for-red-and-black-plugs.326182/#post-4185631

thanks for that,
I've now sent the ECU off to alive tuning, the garage said they were getting random fault codes they could not clear such as ABS, A/C clutch and cruise control, all of which it does not have!
I'll keep you updated,
thanks again,
Callum

Your welcome mate, I know exactly how it feels when your toy is not well, it kind of makes you put all your modifications and plans on hold.
You begin to fall out of love with it etc.
The guys at Alive are world wide recognised experts, and Gary is a total gentleman. My TD5 is going to have its Alive remap done at BHP in Kent, an Alive agent. (see my project thread). I will be doing a write of with lots of pics so watch this space. I am not going to go for a crazy stage 2 type just want a bit more poke and perky response.

honestly its been so depressing, of course it would happen at completely the wrong time as well! now we've got a bank holiday to delay things. Gary should have the ECU by tomorrow though.
I am very interested to hear how the tune goes,

many thanks,
Callum

*update*
Gary has been so great, he got straight on it as soon as it arrived. turns out the ECU is terminally dead.
luckily he has a replacement and will be cloning the data across.

Callum

Thats good news!, problem solved etc
Pass on my regards,

How much will it cost you?

I'm not sure yet, he's suppling the ECU, data transfer and I also said if possible could he perform his magic.
then I've got the cost of the garage which was fault finding since i don't have a nano com etc.

It would be wise to get him to just ensure it has the correct / latest software and fuel map for your car.

If all is well get it mapped, properly, you really need it on a 4x4 MAHA rolling road to get the best out of it.
BHP will run it on MAHA and also take it on 'test flight' drive. Steve will send the real time recording of test flight and MAHA results to Gary at ALIVE, who will prepare a custom map for your specific vehicle, then BHP flashes your ECU with your customised maps.
Back onto the MAHA rolling road for testing and tweaking if required.
They do all this in a day, and its fixed pricing too. (of course Alive may have an approved partner closer to you than BHP in Kent etc) If you have a 'distance' map its never going to be as good as if done will full diagnostic and rolling road, I was this advised by Gary.

PS give the nanocom a swerve, can cause more problems than its worth, look for a Delphi diag kit (its what BHP use) just my opinion of course I know lots of people who have them, but as i said before I would only use it for 'read only' just hear too many horror stories about using it to program injectors or upload maps.

https://www.hickleys.com/diagnostics/delphids150.php

You can find MUCH cheaper 'versions' AKA clones for about £80 on fleabay, my one was £90 complete with the laptop and shed loads of other diagnostic and fault finding software ( google 'WOW wurth' ) etc.

You can normally find someone on here thats local that has a diagnostic, the going rate is normally a couple of quid for diesel and a cuppa!

C.McGrory said:

thanks for that,
I've now sent the ECU off to alive tuning, the garage said they were getting random fault codes they could not clear such as ABS, A/C clutch and cruise control, all of which it does not have!
I'll keep you updated,
thanks again,
Callum

Click to expand...

PS Thats normal, and you cant clear them the garage should know that!
You will always get codes thrown by the ecu for 'missing' stuff that you don't have fitted, they are not 'faults' otherwise your MIL light would come on!
The ECU is just doing its job!

The clutch one is a bit odd though, you do have a clutch switch which drops the revs / changes the fuel when you depress the clutch etc, if your clutch switch is not working could be related etc, they are cheap and a doddle to fit.

https://www.landyzone.co.uk/land-rover/clutch-switch-reverse-operation.191605/page-2#post-4182325

Interesting reading!

it's actually the A/C compressor clutch that the fault code was for, so like you were saying it just a redundant thing.

I'll let you know what the distance map is like, I'm not interested in max numbers, i could still manage to embarrass clio and saxo chavs! perhaps with a remap i can take on fiesta chavs

Callum

C.McGrory said:

it's actually the A/C compressor clutch that the fault code was for, so like you were saying it just a redundant thing.

I'll let you know what the distance map is like, I'm not interested in max numbers, i could still manage to embarrass clio and saxo chavs! perhaps with a remap i can take on fiesta chavs

Callum

Click to expand...

yep, thats all I am going for not interested in silly stage 2 stuff, just want a perkier gettaway!