Strange running on my truck....

[John-Szostak]

Hey all!

I'm a paid member already!

I have a strange issue with Big Red, the engine seems to have almost no power. Doesn't matter wether it's warm or cold, does seem to chuck brownish smoke out of the back, and it doesn't like going up hills.

I don't have any warning lights on, I think it could be the turbo (152k on the clock) and the father in law who I got it off seems to think it's the inter cooler that's blocked.

There is a bit of wetness on the end of both sides of the inter cooler and also on what I think is the oil catch/breather just in front of the intercooler on the rhs.

It's a 97 2.7 if that helps?

Help?

John.

 

[briggie]

2 easy and cheap things to check first ......... inspect and clean maf ..... check mini filter in banjo :thumb2

 

[John-Szostak]

2 easy and cheap things to check first ......... inspect and clean maf ..... check mini filter in banjo :thumb2

Mini filter in banjo?

Father in law states it's been like this for the last 3 1/2 yrs he's owned it.

 

[John-Szostak]

Ok, just been out to try and sort the banjo filter.

In the pics it shows a bolt etc, but on mine there was a union and a pipe on it too, no spring nor a filter.

Any ideas?

 

[AlexD333]

Hold fire for a min, I don't think this sounds like a normal fuel issue, wait for lazy ferret to arrive, hehas I/c and oil issues :thumb2

 

[Lazy-Ferret]

Hold fire for a min, I don't think this sounds like a normal fuel issue, wait for lazy ferret to arrive, hehas I/c and oil issues :thumb2

Never had lack of power though...

I think I would start with the following, in no particular order.

Air Filter,
Fuel Filter
Banjo ( I know you have looked at that)
MAF, (if you have one, you say it is a 97 TD, but you also mention Intercooler which would be a TDi, not sure when the MAF became part of the equation)
Air in fuel, check the pipes under the car for leaks, and maybe change the two flexible pipes for clear, so you can see how things are going.

I would even be tempted to check under the wing where the air intake is, and make sure nothing is up there partially blocking it.

If the I/C is leaking, you get a large loss of power, but I would have thought it unlikely to be blocked, as then the engine would hardly run, and to be honest, there should be nothing able to get in there to block it.

I would also check the two flexible pipes that connect the I/C to the manifold and turbo are OK, with no splits, and are sealing when the clamps are done up. I guess to make sure, while you have the I/C off, run some diesel through it, if it pours in one end, and back out the other, then it is not blocked. If you catch the diesel, you can re-use it, the T2 won't worry about a little engine oil in the mix.

Turbo is fairly easy to check out, take the rubber pipe off the front, start the engine, and see if it is spinning. Switch engine off, and see how long it takes to stop, even on tick over mine spins for a fair while once you stop the engine. When it has stopped, try looking for any play in it.

Basically, you need to start from the beginning, and then let us know what you find on each step of the way, but a basic service would probably be the best start.

 

[Banshee]

This would be my plan of attack in this order

Change fuel filter and replace the feed and return lines with some clear 8mm ID plastic tubing - this will then show up any air leaks in the fuel system that could be potentially causing the running issues, I can provide the pipe cut to size, I offer this service for premium members, just drop me a PM

Check for the presence of a Mini/Banjo Filter in the top of IP, this can be accessed behind the power steering pump, it's a 19mm bolt that can be removed using a couple of extension bars and a flexi head on a ratchet

Some of the bolts have the filter integral to them however some need to be fished out with a bent up coat hanger or the metal part from a window wiper

Since you've mentioned the Intercooler, rip it off and empty it of oil if it has any in it, if it does, check the oil breather, also make sure you have no tears in the rubber pipes either side of the Intercooler as these build up pressure and if they aren't on tight or have splits, you'll lose power

 

[Mav96]

seem everyone is forgetting the obvious, just because there are no warning lights or the mil lamp on I would still check for fault codes first :nenau

 

[panelbeater]

just a heads up,the mini filter on both my t2 were up in the bolt that went through the banjo,be aware there is a washer under and above the banjo.
i drilled it out and blew debris out.

 

[Mobieus_uk]

when checking the turbo make sure the wastegate actuator is not siezed and stuck open.

 

[Sweety]

just a heads up,the mini filter on both my t2 were up in the bolt that went through the banjo,be aware there is a washer under and above the banjo.
i drilled it out and blew debris out.

The early TD's had the mini filter & spring inside the pump like in the down loads but the later TDI's the filter was fitted inside the banjo bolt & can easily be over looked when checking the banjo:augie

 

[John-Szostak]

when checking the turbo make sure the wastegate actuator is not siezed and stuck open.

I checked this and it wouldn't move.

I guess this could be the issue then!?!?

 

[AlexD333]

I checked this and it wouldn't move.

I guess this could be the issue then!?!?

Anyone? :nenau

 

[solarman216]

I checked this and it wouldn't move.

I guess this could be the issue then!?!?

only if it is stuck open which is most unlikely, the spring is quite strong so you will not be moving it with your fingers, it needs a fair bit more than that, yours must be a TDi if it has the intercooler, so what pump have you got? look at the maf on the intake is it Bosch or Hitachi, Rick

 

[John-Szostak]

only if it is stuck open which is most unlikely, the spring is quite strong so you will not be moving it with your fingers, it needs a fair bit more than that, yours must be a TDi if it has the intercooler, so what pump have you got? look at the maf on the intake is it Bosch or Hitachi, Rick

My MAF is a Hitachi one.

Had a bit of a fiddle today. Took the air pipes off the turbo, it spins for a second or 2 when the ignition is switched off, and slightly longer if the revs are up when switch off too.

Took the intercooler off, couldn't see any damage and the connecting pipes are ok as are the jubilee clips. Did start it when the intercooler was off, ran exactly the same just with a grey smoke when revving up.

Will have another look at the banjo, would it show any gunk etc coming out of it?

Fuel filter looks relatively new. I saw on an earlier post about changing the pipes for clear ones. Do these go on the pipes from solid - fuel filter?

I thank everyone for their assistance so far.

 

[solarman216]

My MAF is a Hitachi one.

Had a bit of a fiddle today. Took the air pipes off the turbo, it spins for a second or 2 when the ignition is switched off, and slightly longer if the revs are up when switch off too.

Took the intercooler off, couldn't see any damage and the connecting pipes are ok as are the jubilee clips. Did start it when the intercooler was off, ran exactly the same just with a grey smoke when revving up.

Will have another look at the banjo, would it show any gunk etc coming out of it?

Fuel filter looks relatively new. I saw on an earlier post about changing the pipes for clear ones. Do these go on the pipes from solid - fuel filter?

I thank everyone for their assistance so far.

sorry but but all you have observed so far is meaningless, with the intercooler off get someone to floor the throttle while you hold your hand over the outlet from the turbo, you should feel a definite pressure, Rick

 

[AlexD333]

sorry but but all you have observed so far is meaningless, with the intercooler off get someone to floor the throttle while you hold your hand over the outlet from the turbo, you should feel a definite pressure, Rick

And if there is not? A turbo issue? :nenau

 

[John-Szostak]

Ok, got it in bits again. Turbo has pressure (fast air when uncovered) but does not push your hand away from the outlet.

Have also disconnected the MAF and this has made no difference, no eml etc.

Ideas please!!

 

[Banshee]

I'm going to go fuelling issue on this one, have you replaced the feed and return yet with clear 8mm ID pipe and check thee flow of fuel, working from the front to the back is the best option :thumb2

PM me if you need some pipe

 

[John-Szostak]

Id rather have a second opinion on it, but I think it's the turbo that's causing all the issues.

A turbo = forced induction and there is no forcing!

Is there anyone near Burnley Lancashire or surrounding area that could come and have a look see?