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[joff]

I know i have put this up before but i have still not fixed it so its one last go. The boss has got a 51 2.2dti with 111k on it. She (the boss) said she lost power when going up long hills. This happend when she went from 5th to 4th gear. Ihave today replaced all the filters and oil but when the engine was started again the engine management light came on and when driven power is down to about 70%. Other member have said they had this problem and they changed the EGR valve ? what is this and what does it look like and how ish is it  :-/

[TheBoy]

You know my views - as well as checking egr, also check the boost pressure sensor and its pipes.

[joff]

Thanks again TB i will get to fix this i just need to know were the things are so i can get to them. My tis disc is not working on my pc so i need to ask sorry.

[TheBoy]

I think (from memory) the boost sensor is under the engine plastics towards the back.  Been a while since I've seen one of these engines though, so don't take what I say as gospel

[Marks DTM Calib]

The only real common ailment these suffer is gummed up inlets which need removing and chemicaly cleaning. The result can often affect the inlet pressure sensor and the swirl flaps.

[manc]

Not sure on the power loss, but the EGR valve and manifold pressure sensor (same as boost) are in the inlet manifold.
The EGR is on the top of the manifold in the centre, luckily, unlike a lot of pesky petrol's I've seen these have no electronic control, just relies on vacuum. It defaults to closed so if you do take it off check the pintle is sealing on the seat.
The manifold pressure sensor is at the rear of the manifold, again I think it's on the top.
Having just had the head off mine (2 seized glowplugs!) Marks DTM Calib is right in that they gum up, I scraped up to 3mm of clag off the inside of the manifold and even more off the swirl ports and the inlet valve stems were up to 12mm in diameter! It's definitely worth cleaning as much of this out as you can as mine runs a lot better. I found that "Mr Muscle" oven cleaner was pretty good if left for ½ hour or so, but take the manifold off first!

[joff]

Thanks to you all for your help . I have now got all the carbon muck out of the inlet manifold, cleaned the EGR and the boost/pressure sensor. I put it all back together this afternoon and she would not start so i bleed the injector line and in the end she started. then the management ilght came on again so i think it will have to be a code read after i have charged the battery. hope its only the pressure sensor and not the EGR. One more thing how do you stop the alarm when you take the neg lead off the battery or does it always do that, cos it don't say so in the hand book.

[TheBoy]

Thanks to you all for your help . I have now got all the carbon muck out of the inlet manifold, cleaned the EGR and the boost/pressure sensor. I put it all back together this afternoon and she would not start so i bleed the injector line and in the end she started. then the management ilght came on again so i think it will have to be a code read after i have charged the battery. hope its only the pressure sensor and not the EGR. One more thing how do you stop the alarm when you take the neg lead off the battery or does it always do that, cos it don't say so in the hand book.

Ign on. Ign off, disconnect battery within 15s. That shuts alarm up

Hmmm, I reckon there is still a problem if the light is still on

[joff]

100% battery this morning but she would not start so had to call the RAC out. he got it going with some carb cleaner done the turbo inlet bet the EML came on again just after. As i don't have any more time to spend on it we have taken it to main dealer and i just know they will rob me blind. I will post as soon as i get an answer. RAC man thinks it could be fuel filter housing letting air in

[joff]

got word from main dealer today found a hose off under air filter and when put back on EML went out. They said the injector return lines needed replacing so although i had replaced 30% of them last week i told them to get it on with it as we need the car back for next week so should get it back tomorrow at about £190 but they did tec 2 it for £80 even Dick Turpin had a mask! and they said there was no cdes to read? also they told me yesterday that i may need the injector seals replacing at a cost £450 plus vat. For sum reason i told them not to do that!.

[manc]

£450 for injector seals! which ones? I replaced the top injector to traverse pipe seals and the traverse pipe O rings through the head, and ok the cam needs to come out to get to these but the parts were less than a tenner. Or do they mean the injector washers?

Glad to hear it may be sorted though.

[joff]

Don't know which seal they are on about! The last injector seals i did was on a generator on a type 42 (thats a war ship). They told me the injector seals were £6.90 each plus vat and the other item was 48p each and also the rocker cover gasket. All that with 5 hours labour would cum to £477.25. so make your own mind up. I must get my TIS to load on my pc. The mig is back home now and seems to be running fine. All they did was TEC2 code read push a pipe back on and replace the leak off pipes with new total bill £174.63 thank you very much Dick Turpin.