Hey everyone!

Been enjoying the forum for about a year now since being the proud owner of a shiny 03 Stilo 1.9JTD 115 :slayer:
The forum has been an amazing tool, and have been able to sort many niggling problems by searching alone, so thanks to all involved! However, I fear i now need some direct advice!

For a month or so now it has seemed a little sluggish and the other day i noticed that the little black vapor box near the air filter box had dragged on the floor and now has a hole in it. So i cable tied it back up and temporarily duct taped the hole up, allong with replacing the air filter.

The next day, about 2 minutes after starting the engine stalled, i have not been able to restart it since. Every time i try, the engine will start fine and run perfectly for about 10-15 seconds, starts juddering, produces loads of white smoke and stalls. It also leves black deposits where the exhaust gas hits the ground. The engine will then not restart for about another 15 mins when it will do exactly the same!

All the levels etc are fine, no oil in water / water in oil etc. About a quarter of a tank of fuel. The ony fault codes i get are: P0530 - Air Con pressure and a stored code for The Supercharger Pressure P0235. The fuel pump makes a whirring sound when the ignition is on and the fuel pump relay makes the same noise when actuated with FiatECUScanner. I have also replaced the air filter to make sure nothing was blocking it and cleaned the MAP Sensor (just incase lol)

I am now totally stumped, I have a feeling its fuel related but not realy sure where to go from here and any advice / suggestions would be much appreciated :worship:

Chris

have you checked your intercooler pipe to turbo for any holes, mine popped off yesterday and it became horrible, stalling plumes of smoke and very noisey sounding very similar to your problem.
its a very common problem for the inner wheel arch to wear a groove into the pipe and cause this problem.
roy

hi,
A few other things you can check is unplug the MAF sensor and run the vehicle, does that make any difference? Also p0235 could be the overboost valve playing around, have you resited it onto the side of the battery box? Check the pipework that lead to and from the overboostvalve, i mean really check it. If in doubt replace it.
There is guide about resiting the overboost valve if unsure what to do.
Also on the overboost valve there is a foam filter, pop the end of the casing off and give it really good clean.
Let us know how you get on with that first.

Cheers

Kev W

Fantastic! Thanks for your suggestions guys! Just heading out to check them now! Fingers crossed

Thanks for the help guys, have located the overboost valve and checked the two small pipes going to it, they seem completely inact bar one small nick in one of them (it hasnt penetrated through to the centre though) have cleaned the connector with contact cleaner but have been unable to work out how to open it to clean the sponge - sorry to go all technical but do i prise the metal ring off the end of the white bit??

Once cleaned or replaced i plan to relocate the valve as suggested

I also removed and checked all of the pipes going to and from the turbo and intercooler. Where one goes through the wheel arch there is a deep rub mark but again not all the way through, and where one of the smaller pipes joins this there is also some wear (please see pics)

Also, is the MAF sensor the one within the black inlet pipe which connects to the air filter box???

Is this really suddenly enough to cause so much smoke and stalling everytime?

Thanks again

EGR valve jammed open can cause stalling so might be worth blocking it (temporally)

I vote for failed turbo. Black spots of oil out the exhaust and white smoke is a dead give away for burning oil.
Be very careful or you will end up like this X5, running on oil.
[nomedia="http://www.youtube.com/watch?v=M-pxsViKF88"]YouTube- BMW Engine Crash[/nomedia]

With the turbo inlet pipe off, as in your pic above, put your fingers on the turbo impellar (never with the engine running) and see if there is obvious side to side movement.

It should spin freely, with no side to side movement if it is OK.


I suspect it will have a lot of play and may not spin at all. It may have sucked in some crap when the vapor trap was broken.

I am with Argonought,I have just given my stilo a going over,new oil filter, air filter ,new engine oil,gearbox oil,new clutch slave cylinder in the gearbox, had to take a lot of stuff out so I could get in,and decided well lets have a look at the EGR and it was full of S@@TE,seriously give it a clean you will hear the difference , she will be getting more clean air,so your exhaust will be clean as the first snows of winter

seboni121 said:

I am with Argonought

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A sticking EGR valve will never give white / grey coloured smoke. Only burning engine oil does that. Fuel problems always give black smoke.

Thanks for the suggestions guys!

Phew- fortnately the turbo blade seems very stable (no sideways movement) and spins quite easily

Fingers crossed for a cheap solution!!!

Just about to tape up any potential blemishes in the pipes and clean the egr! To see if that helps!

Also, is it worth completely replacing the two thin pipes to it and replacing the whole overboost valve?

Hi,
With reference to changing the pipes to/from boost valve , yes i would.
They are of a hard plastic type which are fine when new but over time they will get "loose" . Just get some replacement pipe with about a 4-4.5mm bore. When i did mine i used a neoprene type rubber and cost me about £4 from a local supplier.
I cannot think of anything else which would be causing your fault but wish you well in trying to sort it.

Kind regards,

Kev W

Sadly temporarily taping the pipes and cleaning the connectors to the overboost and MAP did not help!

Thanks Kev, will change the pipes and reposition the overboost as well as cleaning the EGR asap!

Is there any other way of checking the turbo besides how stable the blades are where the air intake goes in???

Im sad to say it, but with the vapor box having been scraping along the floor for who knows how long, some sucked up rubbish does sound like a possibility

Any other thoughts?

Whilst checking vacuum pipework for leaks is a good idea, overboost issues will never cause stalling.

I'd block the EGR as stated (quite easy - I did a howto somewhere on the forum a while back) but suspect John is correct about the injection of dirt into engine and consequent damage

dancin said:

Is there any other way of checking the turbo besides how stable the blades are where the air intake goes in???

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Take your lower intercooler pipe off and see if there is loads of oil in the bottom of the intercooler. A bit is normal, but a lot is trouble.

Also Identify what is coming out of the exhaust. Is it oil spots or soot?

How many miles has the car done?

Hi everyone,
Sorry for my late reply but spent the weekend dismantling and cleaning out the egr and all pipes to and from it! And, its cured
The EGR (the last bit where the plug goes in) was that caked with soot it was jammed in one position, after much cleaning its now as free as a bird and she runs beautifully!!!

Thankyou so much to all who advised

Would it be worth me fitting one of those modified gaskets ive read about on here somewhere??