Td5 with the wrong head and down on power - Advise needed!

Hi everyone,
I'll start from the top!
I'm a tech and got given a 2000 D2 Td5 auto with no drive. I put a foward drive clutch pack in and presto, got myself a fairly clean motor for next to no money.
The next problem (and the one that this is about) is the lack of power it has. The old girl is not storing any fault codes. I started with the MAF as was not reading, put a genuine on and that now reads but no difference in power. I checked the injector harness, egr valve, wastegate, fuel pump pressure, map sensor pressure and temperature, injector clearances, all ok. Ended up finding the timing a tooth out which did improve when rectified but still not right. It will spin the front wheel when pulling off, and feels good until 3000 rpm. Unfortunately being an auto that is where the stall speed of the torque convertor is so in any gear apart from pulling off, that band of power is reved straight past! It does go just feels like it gives up after 3000rpm like and old non turbo'd van!
So here's the question in the hope of anybody that knows the in's and out's of the Td5.
The car is an eu2 which should have a 10p engine. It has had a replacement 16p engine with the later eu3 cylinder head also but it still has the black top eu2 injectors and injector rocker shaft. Does any body know if this would cause the lack of power I am experiencing?
Also would the camshaft had to have been changed to suit the old injectors?
Is there a way to tell the difference between the two shafts?
Could green top injectors be programmed to my ecu if this is the fault?
I could be barking up the wrong tree and missed something else but any advise appriciated as I am currently tearing my hair out!
Sorry for the story and thanks in advance!

Will also add, no boost leaks, new air and fuel filters, turbo modulator pipes all ok

Sorry and again, this has been ongoing for over a year so the memory is a bit rusty! Intercooler hoses have been checked and not collapsed.

Hi, i dont know much about the pure mechanical side of the rocker shaft but IMO there is some difference cos AFAIK the travel of the Eu3 injector's plunger is longer and the shafts have different part numbers as well.

What i know for sure is that you can't save Eu3 injector codes in the Eu2 ECU but at least you could check if the codes are saved cos a possible symptom of uncoded injectors is lack of power at high revs (see attachment)

you should run a stall test which might give you some ideea(attached as well)

Hi mate, thanks for the reply. It is definately not a gearbox issue.
I know about the rocker shafts and mine has the early one to suit the early injectors, I was wondering about the camshaft and if the later engine might have different lobes for the injector rockers, like you say for the different lift.
The injector codes are ok, another point I forgot to mention! It will rev past 3000 just slowly.
There must be plenty of these cars out there with later engines by now? A work around of some description?
I don't really want to put a 10p head on it due to the cracking issues.
Not being able to code later injectors is a worry if this is the fault...
Any suggestions people?

What's the MAP reading at 3000rpm ? also is the AAP(airbox sensor) reading dropping under load ?

I can't remember the exact figures as was a while ago but the MAP and AAP were both where they should be (looked them up on topix) across the entire rev range.
It does not smoke at all I should add which points me towards an under fuelling issue.

That's strange cos as long as the MAP reading so the boost too is where it should be there's no reason to be no power once the gearbox is working well, underfuelling would affect the boost in the first place as long as you are sure there's no leak, it's practically impossible to be underfuelled with correct boost if you see what i mean, it can be overfuelled with low boost but not vice versa, i recommended the stall test for confirmation cos one of the results points to reduced engine power

Hmm, not sure I agree with that. The turbo will still produce boost pumping out exhaust gas at 3000rpm, having a lean mixture would not affect that.

Then i can't add much as it seems that we have different conception about how the Td5 management works, the MAP reading on Eu2 is part of the IQ calculation so there must be a balance in the MAP/IAT and rpm relation, If you have a correct MAP reading at 3000rpm under load there's no way to be underfuelled cos the fuelling is based on airmass calculated from MAP reading and the ECU has compensation maps within. It's a long and complicated story i wont enter in it here. Maybe the best for you woud be to get hold of a Eu3 ECU change the injectors and wire in the AAT input for the 4 pin airbox sensor.

I understand what you are saying but an engine can still rev up with a weak mixture but will lack power. Basically I just need some answers regarding the the camshaft and injectors. Thanks for your time though!

Burt123 said:

an engine can still rev up with a weak mixture but will lack power

Click to expand...

I agree with that but then the MAP reading is low too like when it's stationary so no boost, you can rev it up to 4000 stationary but the MAP will be low while if as you say at 3000 rpm under load the MAP reading is OK then it can't be underpowered cos then the MAP would be low... though i see you are already convinced so i'll not insist on this and unfortunately i know nothing about the camshaft thing

Hi guys, long time no speak!
So after hitting a brick wall and living with this lack of power, I finally got my hands on a like for like, known good model! Wait for it... It's exactly the same!
So I have been chasing a non existant fault, what a cock!
Luckily I haven't thrown any parts at it!
Thought I would update as there is nothing worse than a thread trailing off without a resolution.
Sorry for wasting your time!
Cheers,
Zacc

Burt123 said:

Hi guys, long time no speak!
So after hitting a brick wall and living with this lack of power, I finally got my hands on a like for like, known good model! Wait for it... It's exactly the same!
So I have been chasing a non existant fault, what a cock!
Luckily I haven't thrown any parts at it!
Thought I would update as there is nothing worse than a thread trailing off without a resolution.
Sorry for wasting your time!
Cheers,
Zacc

Click to expand...

I was going to reply I test drove an XS auto td5 many years ago, and could not blelieve how flat it was, all revs and no go.
Great engine, terrible gearbox combo

If you look at Turner Engineering they only offer one camshaft for TD5 which they say is suitable for all engines: https://www.turnerengineering.co.uk/lgc000310-camshaft-c2x25801865, there is an earlier cam but its says now obsolete.
In Rave it tells you that the green top injectors are a much higher pressure than the black top ones and must be paired with the correct shaft and rocker arms.
One thought which ECU and map do you have ? the later engines use a later ECU which can be re programmed if you still have an older ECU then it may be using the map for a 10p engine not 100% sure how much this would influence the engine but pretty sure it would not help.

Terrible set up but I love the old turd