First time I had any mechanical problems with the engine (1.9jtd cargo).

Basically noticed the acceleration had gone but the top speed is the still there and a top end tapping sound after about 1500-2000rpm. I'd guess the turbo has failed but not sure about the tapping sound which is more like valve or cam type noises. There is no smoke or oil problems from the exhaust.

Anybody out there can confirm the sound of a failed turbo or had a similiar problem who can shed any light?

Cheers, Franc

i don't think its the turbo as you would loose alot of power, try disconecting the afm sensor (there's alot of threads on how to do this) as for the tapping check oil level and condition or you could need the valve clearences checked

Latest update:-

disconnected the plug connector to the MAF but the only thing that did was to produce black smoke from the exhaust. No noticeable power difference but maybe revved a bit more in neutral.

Changed the cam belt just to make sure the belt hadn't slipped. Replaced 2 of the small pressure pipes to the turbo as they had signs of wear.

Felt the EGV and it did not get hot whilst on tickover for about 6-8 minutes.

Anybody got any other ideas to try?

Have you tried completely disconnecting the EGR valve to completely rule it out? Whilst sat at tickover it my have got stuck in the closed position. Just don't drive around with it disconnected permanently as it is illegal

As for the tapping... who knows, valve clearance?

Latest update:-

replace the afm and the EGR valve but still no joy. Still doesn't want to rev past 4000 rpm.

Cheers, Franc

in the mean time:-

Been driving it about (well got to make a living!). Went through a small ford and 2 minutes later the engine would not rev past 2000rpm. About an hour later back to revving at up to 4000.

Starting to make me wonder if the tapping & lack of power could be the injection pump?

The tapping seems to get louder when the engine is at normal operating temperature.

Any more ideas anyone?

cheers, Franc

Hmm, the fact you went through a Ford and then encountered problems still screams to me 'electrics' but I'm no expert

As has been said, tapping I would say valve clearance, especially if it's more prominent when the engine gets warmer, the oil is warmer, components are warmer and things expand! If the valve clearance isn't correct then it's possible this could be causing the lack of rev's available to you, as the JTD should rev to 5000ish before it hits it's limiter.

The funny thing is that the lack of power and tapping sound both started at the same time so to me it screams mechanical.

But then the fact it went even more sluggish today indeed does suggest electrical. Today I drove with the AFM disconnected. Tomorrow I will connect it again. The sound is there regardless of connected or not.

The tapping noise is hard to explain, maybe I'm misleading in my description. The best way I can describe it is to press your tongue on the roof of your mouth and make a drrrrrrr sound! It is bearly noticeable at tickover but audible at 1400+ revs to loudest at 4000rpm.

I disconnected the auxillary belt to rule out anything on that side, so only leaves something on the cambelt or cam itself.

I will take the rocker cover off on Tuesday and have a look, is there anything I should be looking for in particular?

Cheers, Franc

FRANTIC FRAN said:

I will take the rocker cover off on Tuesday and have a look, is there anything I should be looking for in particular?

Cheers, Franc

Click to expand...

look for wear on the cam lobes

When I press my tongue to the roof of my mouth & make a drrrrrrr sound, it's reminiscent of a dodgy exhaust!
Not having had change to grease my hands on dobbin yet, I'm surprised that you'd need to adjust the tappet clearance (them were the days when you could whip off the rocker & adjust the tappets with the engine running. Nowadays it seems to stall the darned thing!)
Anyways, I'm amazed that Fiat didn't use hydraulics on the tappets. Ok, it clatters a wee bit on startup but as soon as the oil gets in there it's fine.
(this being my first diesel, I assumed the unmistakeable clatter of the oil burner was down to hydraulic lifters)

Actually now you come to mention it you're right, they should be hydraulic, that's why when the engine is cold it clatters a bit for about 30 seconds on startup!

Have you checked your exhaust? You never know

Ozzie1989 said:

Actually now you come to mention it you're right, they should be hydraulic, that's why when the engine is cold it clatters a bit for about 30 seconds on startup!

Have you checked your exhaust? You never know

Click to expand...

Ooooh, Oooh - does that mean I'm right for once?

the clearences have to be checked every few services, as specified by fiat

Yep it's dead!

After a day or 2 the afm maybe started to work a bit. Acceleration was pretty good between 2000 - 3500 rpm but dead below 2000 or above 4000.

Drove it around a few days until...... Bang! All I know now (until I remove the head) is that the cam no longer turns when the engine is turned over so either the belt has snapped or one of the pulleys broke.

Looks like for now anyway that the valves were sticking or maybe bent?

Does anyone know if these damage the piston heads in such instances or just a case of getting the head sorted?

Also what other Fiat models have exactly the same engine? Multipla, Marea?

Cheers, Franc

Oh dear

Not entirely sure on the piston situation, I shall take a look at my workshop manual to work out how the valves are placed within the head.

1.9JTD's were used in the Stilo, Punto... not sure about the multiplas and the other vans used the 2.0 or 2.2JTD???

Has the timing/cam belt been replaced at the correct time? Does the vehicle have a service history as the valve clearances should have been checked according to Toad and possibly problems could have been spotted if they had been checked?

Let us know the story...

When the auxiliary belt tensioner failed on Mrs O's 1.9JTD I discussed this with the Tech and he says that if the Cam Belt goes it is piston v Valve!!

I had a look at the workshop manual and it doesn't show the positioning very well so it wasn't much help, but if a tech said that then it's gonna be the piston heads too

I fear you are right! Took off the rocker to discover that the belt is turning fine but yet the cam stays still!!! There is a damaged valve bucket on no. 7 (1 being the cam wheel end).

Maybe this engine is heading towards fiat's final resting place!

Cheers, Franc

The timing belt must have slipped if it's not broken
Like Oz said, your engine was used in the Punto etc. if you think it's worth doing.
Found a Stilo engine on ebay

I used to have a mazda b1800 pickup. The previous owner had never changed the oil so the oilways were gunged. The cambelt tensioner relied on oil flowing so I was basically driving with a sloppy belt.
Slipped two teeth at 70 on the A1.
When I eventually got the head off (had to saw through the stretch bolts & use mole grips to get them out!) I discovered every valve had hit the piston crowns. Although this only bent the stems fractionally, they were impossible to get out.
Ended up buying a lump from Auto trader (pre-ebay days).
If you find time, take the head off & look at the piston crowns.