Hi and praise be for this forum!

2003 estate.

Drove it approx 4 miles after purchase and no issues until power loss followed by black smoke from exhaust and loud rattle from engine.

Switched her off for 2 mins and drove home with no probs.

From then on, car has struggled to make progress as though the diesel isn't getting through and there's plenty of black smoke and the loud rattle under load. When it's ticking over whilst stationary it sounds fine.

I've cleaned out the EGR and MAF, replaced the fuel filter, oil filter and oil all to no avail.

HELP!!!

would be worth checking pipe work to intercooler as a tendency to rub on wheel arch liner on passenger side that can cause a leak in the pipe work
This thread below has some details especially post 13 which is similar to yours seeing as you have gone through the service stuff already
https://www.fiatforum.com/stilo/254667-jtd-intercooler-hose.html

Although this thread says nothing on engine rattling ..take it you have no fault indicators showing on dash

Pipe seems OK.

I'm wondering if the engine is actually kaput given the rattle?

Cheers for the reply.

Are you able to tell roughly which area the rattling sound comes from..would it be i.e crankshaft pulley / cambelt side

Hi. Forget cleaning the EGR because you still won’t know if it is working or not, just blank it off then you can forget about it at least until the engine is running right, it takes about 20 minutes and cost nothing plenty of how to threads on here just search.

EGR problem is very common on the jtd and will cause power loss and black smoke and rattle, if the engine sounds O.K when ticking over I doubt you have a serious problem, any warnings on the dash?

as above, the engine rattle is most likely the engine struggling under load-if the egr isn't functioning, and you are trying to make the engine go faster, its going to struggle like its hard to breathe...!

It sounds like a big end rattle to me but now you've got me thinking with your comments about a duff EGR causing smoke and rattles. That said, I'm getting an occasional 'low oil pressure' dash warning and the car has less power that a double 'A' Duracell battery!

Only other dash light is the usual airbag and occasional 'preheat failure' problem (no starting issues at all).

I can't tell where the rattle is coming from as it's only apparent under load and I'm driving it.

I think I'll try the blanking off jobby and see what happens then.

Would a duff MAF cause the same symptoms?

Many thanks for your help so far.

ah ok interesting updates, obviously check the oil, perhaps even change it.

A MAF will certainly affect your performance no two ways about it and will contribute to smoke out the back, low power and general sluggishness, so well worth checking that as well-give it a clean for starters, if no improvement, buy a new one. definitely blank off the egr, buy three plates (I think it is, or is it two?) and fit them appropriately to blank it.

I flushed the engine and changed the oil when I did all the other stuff I've mentioned.

Pulled the MAF connector off and still same issues present.

I was gonna do the EGR blank with a home made bit as a tester, as per the post on here.

Ta.

if you unplugged the MAF, and there was no change, its likely you have a buggered MAF.

Hi. just blank the EGR first then you can forget it as the problem, one blanking plate on the corrugated chrome pipe two Allen bolts.

https://www.fiatforum.com/stilo/227396-egr-blanking-jtd-5.html?p=3245124
post 75

If that doesn't cure the problem then we know one thing it is not.

Never heard of the ends going on the JTD very tough engine, but I guess we don't know the history so maybe.
I assume you have the right grade of oil in it.

I'll try the EGR blank as I said before and take it from there.

Used Castrol 10/40 semi, so should be OK.

Again, muchos gracias for your help so far.

Fellas (I'm assuming you are - apologies if not!)

I love ya all (in a manly way, obviously!).

Blanked off the EGR and she's flying now. Total transformation and what a relief. I thought the engine was a goner.

These forums are absolutely invaluable.

Thanks, thanks...(repeat to infinity and beyond).