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Discussion Starter · #1 ·
Hello

Looking for a bit of guidance.

Less than 12 months ago this previously reliable vehicle with only 107 thousand miles gave out with major fuel injection problems.( fuel pump ate itself and contaminated entire system ) After shelling out a fortune at local garage for new fuel pump, injectors, filter plus other ancillary items including tank removal and clean out. Fuel pump and injectors were Delphi factory recon parts

The car has from that time run satisfactorily with good economy and fuel performance only using Shell or Esso fuel as I was advised not to use supermarket fuel.

I had noticed on occasion recently that pulling away from junctions or standstill that the car was emmitting a cloud of smoke but not during normal driving. Exhaust emmissions checked ok for mot in March. Have now only covered another 7000 miles since overhaul.

Yesterday things got worse, the car now trails dark smoke and even worse starting off , judders at times on even throttle as would a petrol car with a slight misfire and also is a bit down on power. There are no lights coming up on the dash indicating a fault at this time.

One other thing, during a cold spell in January twice the car dropped into limp mode and was fault code diagnosed by garage as requiring a new turbo, however a second opinion taken from a man specialising a bit more in fuel injection and turbos correctly diagnosed it as a sticking turbo regulator arm which was dealt with at little cost and up till now no further problems.

My first thoughts (apart from setting the car alight) are to have a leak off test done on the injectors to see if any are the problem.

I would be pleased for any further advice.

Mike
 

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Unless there was some remaining contamination factory recon items should last much longer than 7000 miles, but I agree a leakoff test is a good idea. Checking hoses for boost leaks, and try fitting a blanking plate, would be my other suggestions. If you have access to a windows laptop, a usb diagnostic cable (either elm327 or f_super) is £15 or less on ebay and will let you read codes yourself and see some live data which may be helpful.
 
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Yeah if the fault was just sticky vanes i would not have required a complete new

turbo. They can be cleaned and will be as good as new after.

Split boost pipes can cause issues, it may start as a small split and a slight drop

in performance, you may not notice at first.

The one on the left/front of the engine that connects the EGR to the intercooler

is the most common one, but any of them can split, I had one pop off

on my old car.
 

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Discussion Starter · #4 ·
Thanks for you suggestions, Having a look at it today myself, clean out egr valve , manifold, check hoses and leak off on injectors before going to garage. I'm afraid I have spent so much on this car I am very reluctant to throw more at it.

Trouble is its a really tidy motor which I was just preparing to sell on, sods law I suppose. Previous two I have owned combined covered 400,000miles plus and hardly any bother from either one.
 

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I helped a member on Sunday and his car didnt like the EGR being connected

until it was warm, even then it made a slight difference to the idle.

It wouldnt start at first, Got it running with the EGR vacuum pipe removed, put it back

on as soon as it started and it started to run rough and started to stall.

Removing the pipe again and the idle picked up and settled out.

So dont take the EGR for granted, Any issues just blank it off and see what difference

it makes.

Similar issue with the injectors also, Helping another member and swapping an injector out

can sometimes cause it not to start at all. Just one injector. Refit the old one or fit

another one and it started instantly.

Fitted one and it started up lovely, Nice smooth idle, But then it had a little hiccup,

1st thoughts its just clearing a bit of air from the pipe, as it settled to a smooth idle again.

then a few seconds later it did it again.
 

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Mine idles nicely with the inlet manifold off (easy with rear mounted egr). No cost test for idle issues provided you don't either suck something nasty in or get tempted to rev it and overspeed your turbo...

Going back to problem for a moment, do you have a code reader? If you've had sooted up turbo vanes once, they sometimes recur. If you can get codes read with f_super or an elm327, may shed some light...
 

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Discussion Starter · #8 ·
Hello again

Dismantled and thoroughly cleaned egr valve, and inlet manifold. which was a bit clogged but I have seen it worse. checked turbo pipe below egr but it was not until I managed to get a small mirror and light to inspect that I found a split about 40mm long. In order to get at the previously poorly positioned bottom hose clip screw I had to lift car and remove both under trays, so gave the other hoses a good inspection while I had the opportunity. Also renewed gaskets on inlet manifold as the old ones looked past their best and I suspect had been letting by a little.

Ordered in a replacement pipe and fitted yesterday. The car was very smoky still when started but after about a 10 mile run it now seems back to normal. Only a slight puff of smoke when starting off now. An intended 200mile run later today should sort things out one way or another. Have yet to try a leak off, on the injectors which may not now be necessary.

Thanks for all your comments, very helpful.

Mike
 

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Glad you've got it fixed!
 

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Hi all used just like to say wot a great site this is used it a lot since I've had my 02 tddi ghia x estate been great help. I've owned the car for about 3 years it's done 155000 miles and apart from broken front springs. Wheel bearings new battery and service parts been no trouble. That was until the alternator give up about 7mths ago so went to euro car parts and got a rtx one big mistake but didn't know they where bad at the time . Anyway since its been on the battery went flat about 5 times over night random also had a miss fire/lumpy idle then the battery light came on again. Phoned euro car parts about warranty on atx alternator it's 12 months found my invoice and took it back changed it a bosch unit had to pay £70 odd more they wavered the £40 exchange charge. Since putting the new alternator on the miss fire has gone the flickering lights has stopped the car runs better then ever now even the central locking works all the time was about to start striping egr and cleaning out pipes and manifold lift pump ect to try and find out why it it was miss fireing fuel fitter and and service parts had already been done glad that rtx alternator packed up now.
 
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