no your not going that crazy that was the egr thread and it was the thin wire on the alternator that broke not the accelerator

Well the thin wire that broke has been repaired and fitted that way for some time now, although it might of damaged the fly by wire wherever that is, im not sure.

Well now it just seems choked all the time and to get it to accelerate is a mission, its amazing how much smoke can come out of an exhaust, i mean im not talking little bits we're talking big clouds of the stuff all the time when the egr clicks.

I used to beable to sit there in neutral and rev, but if i do that now it clicks, smokes and cuts out. even tried swapping the vacuum pipes on the actuator works to a degree but not much.

I can get the van up to 80 on the motorway by getting there gently, or with high revs just making sure i come off the clutch really slow. but as soon as i want more to overtake or go up a hill, that it wont do it. so i dont think its in such a position, just when you want he power it cant give it. or its getting blocked somewhere as now it does it in neutral too.

come off the motorway and its just rough as hell, too much acceleration and it just gives up. it sort of feels like the exhaust is blocked to buggery and its backing up, if that makes sense.

Im not sure if its had its day really and it wants to die. but that means i'll have to go and try and buy another van that i like. and theres not many only seen one that looks ok, and thats a peugeot 350 2.2 lwb 06 plate.. was hoping to get mine fixed cheapish so i could at least part ex it in..

almost forgot a mechanic that was there when i was fitting the sensor to mine said that sounds like its missing.. wouldnt i get a code if it was?

Hi. what colour is the smoke?

The smoke is grey, i get the odd bit of black mixed in now and then. The exhaust when being rev spits out black **** as you can see it on the ground.

Now after running crap and cutting out all day, ive just been out and it only cut out once, i didnt press the accelerator hard but it drove better although still rough. cant weight it up, just when you think your getting somewhere it cuts out again

Good that the pressure sensor got it out of limp mode that money needed to be spent anyway, did you clear the codes since you changed the sensor? Hopefully it won't come back.

Your egr actual says it was fully open all over the place in the second air test, you need to blank that off instead of drawing fresh air with 20% oxygen its drawing exhaust fumes so you can't burn all the diesel hence the smoke.

All that smoke is unburnt diesel which can dilute the oil in the bore causing wear, you need to sort it.

Actually I've been working on the assumption that yous has no throttle body between thevturbo and intake as its a 06 but it could e an older van registered in 06. The click you could be hearinag itvthe throttle body solenoid closing the butterfly.

Yeah i graphed the fuel pressure and signal as you advised and they were pretty much dead, but i had volts going through the plug, so yeah the pressure sensor was dead. no getting round spending for that one as you say

When i blanked the egr off last time it still smoked and clicked just the same, like it was blowing the other way. which is why i thought it might be the egr vacuum soleniod thing.

Which is the throttle body soleniod?

im sure a guy i know said it could be something to do with that before (he has a ducato mh), it was that or either an acelerator wire or something.

oh and yes i put it straight on the fiat machine after a changed it and cleared the codes, and now it comes back up with P0191 which we know it isnt as ive had that checked already.

Yeah mines the same as an 05 engine, as i was looking for other vans. i always thought it was 07 they changed the engines and van looks.

Well there is just no power in the van when setting off and you can feel what is like a rumbling when setting off in the lower gears, but there isnt any power/boost at all, seems just so blocked somewhere.

I took the big air pipe off the manifold and it smoke like buggery (is that right?)

well im stuck now and not sure where to look. apart from disconnect the exhaust/cat and see if that helps any.. or change the egr vacuum soleniod valve..

Smoke from the intake? That because the egr is fully open.

The got rid of the throttle body for the last year or so of the 02-06 model.

If yours has a throttle body then make sure its fully open and disconnect and plug the vacuum hose from it otherwise when you blank the egr you won't have enough air.

moodrater said:

Smoke from the intake? That because the egr is fully open.

The got rid of the throttle body for the last year or so of the 02-06 model.

If yours has a throttle body then make sure its fully open and disconnect and plug the vacuum hose from it otherwise when you blank the egr you won't have enough air.

Click to expand...

no smoked from the exhaust.

Not sure if mine has a throttle body then, as one pipe goes from the vacuum soleniod to the egr, one is a breather pipe, and the 3rd one goes to another pipe that it gets the vacuum from.

mwooly10 said:

no smoked from the exhaust.

Not sure if mine has a throttle body then, as one pipe goes from the vacuum soleniod to the egr, one is a breather pipe, and the 3rd one goes to another pipe that it gets the vacuum from.

Click to expand...

Without a map the ecu estimates boost from fuelling and rpm so when you disconnect from the turbo you have no boost but the ecu thinks you do and puts in too much fuel.

If you still have p0191 its probably because the duty cycle of the pressure regulator higher than the map in the ecu expect/allows to maintain pressure, which is probably a leaky injector.

Throttle body is number 4 in the picture if you have it:

On mine is just a big silver pipe (which is the one i disconnected from, so hence why it probably smoked having way too much air) that connects to the turbo and egr cooler, if im right. and the other way tees into the air filter pipe.

so i dont think i have one. I cant visally see any leaks on an injector unless its inside.

so really given the age, well milage that could be one of a few problems that could turn up then

Well your either very intrigued to find out the problem, or are getting a bit bored of me by now

Have been looking at other vans, just in case as cant be without mine, not many i like that are about, think i have it down to a 2.2 boxer lwb or a 2.8 ducato lwb. as im not sure even if i get mine fixed it would last a lot longer, would be nice to fix it if i can, i could at least sell it or px it in then.

Right ok.

Ive just been out and stuck my hand over the air intake pipe thats attached to the air filter housing and it made the pipe going to the manifold (number 3 in your diagram) suck together so doesn't look like theres a leak there.

Then i squeezed the manifold pipe (no3) and it lost all its power but still ticked over, then wiggled the other end the plastic pipe that goes down round the back. now ive just nipped out in the van and for the first few hundred yards the engine sounded and felt a bit like it used to be, much more responsive, although still had the clicking a bit, but after that it ran like a bag of nails again.

What i want to know is, after the air has come in through the air filter and its gone up through into the manifold, is there a chance it could be blocked somewhere and it is backing up and making the egr click? or is that me just thinking too much and thinking it was something id done?

Just want to help cause I know what its like putting money into an old vehicle, even putting a couple of hundred euros worth of tyres on an old van can be a gamble :-o

The injectors leak a little of the pressure from the rail into the return pipes a brand new injector leaks almost nothing, up to 20ml per minute is ok. If you remove the clip holding the return pipe on the injector and pop out the return pipe you can eyeball how much diesel is welling out of each injector. Usually you'll find one much worse than the other. If they're all similar you'll have to resort to using tubes or bottles to measure the quantity of leakage.

When the injectors start to leak badly the pressure regulator has to open more to compensate for the pressure lost in the rail. Eventually you reach a point where the ecu says there must be something wrong.

Theres a good pictorial of a diy leakoff test here:
http://www.peugeotforums.com/forums/engine-53/diy-hdi-injector-leak-off-test-20757/

The nozzle can also leak dribbling diesel into the cylinder that you cant see and is the worst.

mwooly10 said:

Then i squeezed the manifold pipe (no3) and it lost all its power but still ticked over, then wiggled the other end the plastic pipe that goes down round the back. now ive just nipped out in the van and for the first few hundred yards the engine sounded and felt a bit like it used to be, much more responsive, although still had the clicking a bit, but after that it ran like a bag of nails again.

Click to expand...

Do you mean number 6 in that case you might have an issue with air mass sensor or wiring, unplug the air mass and see how it runs looked alright in the air test but hard to know with the egr opening and doesn't capture momentary problems. You can get a special air mass cleaner in the motorfactors if it looks grotty, the pcv can spit oil in there.

Thanks for the info on the leak off test, explained it well enough, even i should beable to following that

Also thanks for all the help so far

As for a faulty MAF, that is new so i doubt it is that and still runs the same with it disconnected, as for the wiring well thats still debatable.

No it looks more like number 3 in the first picture, the one that attaches to the egr cooler and turbo.

When i drove this afternoon, nice sunny day for a change, it smoked as soon as i turned it on, but after filling the carpark with smoke, it seemed to be a lot smoother running for 5 mins, it is a weird fault.

Think im gonna run out of time and have to get another van, but i think im still gonna have a go and fix this one, just wont be as rushed. as i cant sell it, so if i cant fix it, it'll do as a bit of a donor van for the next one

The only reason i questioned it being a blockage, is that i havent had the cat or exhaust checked yet. it never got that far in a garage, and ive just been trying to test what i can, which is only what i can get too or see

mwooly10 said:

Thanks for the info on the leak off test, explained it well enough, even i should beable to following that

Also thanks for all the help so far

As for a faulty MAF, that is new so i doubt it is that and still runs the same with it disconnected, as for the wiring well thats still debatable.

No it looks more like number 3 in the first picture, the one that attaches to the egr cooler and turbo.

When i drove this afternoon, nice sunny day for a change, it smoked as soon as i turned it on, but after filling the carpark with smoke, it seemed to be a lot smoother running for 5 mins, it is a weird fault.

Think im gonna run out of time and have to get another van, but i think im still gonna have a go and fix this one, just wont be as rushed. as i cant sell it, so if i cant fix it, it'll do as a bit of a donor van for the next one

The only reason i questioned it being a blockage, is that i havent had the cat or exhaust checked yet. it never got that far in a garage, and ive just been trying to test what i can, which is only what i can get too or see

Click to expand...

With all the unburnt fuel the cat core has probably choked or collapsed from the heat of catalysing all that fuel at this stage anyway.

The new van your looking at is it the 2.2 multijet, thats the same engine as the transit you almost guaranteed to run into similar egr issues with that one. If it has a dpf you have whole heap of extra shennanigans. From what I've seen of the denso stuff it would be nothing short of a miracle if that van reached 270k miles without a couple of sets of injectors and a pump. The way diesels are going well have to go back to petrol.

Yeah i quite liked the new shaped, lots more room/storage in the front, until i read that it had the 2.2 transit engine. That kind of put me off as people have said they arent that great.

Think i'll try and stick with trying to get and 05 or 06 jtd, least i know they should do what i need it to do.

Your probably right about the cat by now, well the exhaust and cat are original, so cant be much life left in them, i may undo them and see if it improves it a little. But think i'll try and get another van over the next couple of days then i've at least got a working van then i can mess to my heart content with the old one. no danger of breaking it, its already broke

Well it doesnt seem to be the cat or exhaust as i unbolted the cat today and it still was the same when i put my foot down.

So it looks like it may be wiring or faulty injector like you said. Im gonna take your advise although it may be a bit late for the engine, but im gonna get a proper blanking plate to blank the egr off. last time i left it all connected, do you take the copper pipe off and leave the egr open on one end? or just leave it all connected up?

anyway better look for a van so i have one to use properly

moodrater said:

With all the unburnt fuel the cat core has probably choked or collapsed from the heat of catalysing all that fuel at this stage anyway.

The new van your looking at is it the 2.2 multijet, thats the same engine as the transit you almost guaranteed to run into similar egr issues with that one. If it has a dpf you have whole heap of extra shennanigans. From what I've seen of the denso stuff it would be nothing short of a miracle if that van reached 270k miles without a couple of sets of injectors and a pump. The way diesels are going well have to go back to petrol.

Click to expand...

Misread your post. no its the 05 and 06 2.2 hdi, same as the jtd. as i said i like the new shape just not the engine so i gave up on that idea

well not had much time to have a look at the van as been busy but today i got hold of a second hand boost/vacuum soleniod and it seemed to be a little better but not a great deal.

The EGR still clicks and cuts out, the white/grey smoke now doesnt smell of diesel anymore. but when i took my oil cap off that was smoking a bit and the indicator on the dash says its always full, but when i look at the dip stick it looks nothing like full.

Drove on the motorway today and it did quite well even did a little speed up in 5th but still no star for having a race yet

Someone i know said have i looked at the accelerator pedal. anyone got any experience of those going funny?

Just a quick update.

After it getting worse and smoking quite a lot especially for the first 10 mins at least whilst driving, and once you get it up to speed it started making a sort of humming noise if i did over 80, it finally got traded in.

I looked at a few vans that sounded ok, but the doors wouldnt open or shut properly and one had been bodged with silicone(probably hoping no one would notice )

I finally found a van and told the bloke about mine and he was ok with that. so got there and there were a few bits broken, but he let me take the following off my van to compensate/fix it, (2 door handles, wheel jack and brace kit, spare wheel and stereo)

I now have a 2.8JTD 2003 van, body work is good (all paint is there too ) clean interior, and engine sounds ok (its just been on a 600 mile round trip today), didnt think much to the fuel comsumption though, works out at 23mpg on a good motorway run doing a steady 80ish at 3000 revs.

Clutch is a bit spongy and 4th and 5th grind a little if i change too quick, but i can live with that, and the ignition barrel keeps jumping back sometimes although ok once started. but i suppose they are just little jobs to sort out.