Technical AHHHH Sudden massive power loss and black smoke???

[multiplani]

Ok, so if you read through my other threads you will see I have had a very steep learning curve in the short time I've owned this 03 JTD 115 sx Multipla...

And here we go again...

Just 10 minutes ago was en route home from local shop...

Pulled into my driveway and stalled as soon as started up the hill (steep drive).

After stalling 3rd time realised power was way down hence stalling trying to start up hill.

Then noticed black smoke from exhaust.

Can anybody give me an idea what this is???

I've heard about turbo's and egr valves etc showing these signs but I am only learning and don't really know what or where to look on this car (or any regards turbo & egr valve) as there is no manual available.

If its fixable I'm going to have to try and do it myself (steep learning curve continues), but need some advice first on possibilities and where to look, what to check etc.

Or is this a sign the engine has croaked??? Its only got 89000 miles on it.

I would really appreciate your advice.

Many thanks in advance.

 

[disgusted]

Does it get better again once the car is cold?


1/ Are all the air pipes on and free from splits?

2/ If that's OK, I'd start with the MAF. Take it off & clean it. A common reason for poor running.

No change?

3/ EGR valve would be my next choice. These get "sooted-up". Very common. Can be cleaned, replaced or blocked off.

Still no change?

4/ Turbo actuation valve (?) thingy or Turbo itself. I've had no personal experience of this though.

Don't lose heart. The engine in its many variants is common as muck, so it's not a weird FIAT only matter (just about every diesel Vectra & Saab - I think, has them). Parts are relatively cheap and mechanics' experience of this engine is widespread.

If you have a buddy with an OBD scanner/reader, it might be useful in fault-finding.


Good luck...

 

[multiplani]

Thank-you disgusted (nice user name...just how I feel right now...ha!)

Car is running with very little power at all. Took short test run...went down my road (downhill) ok but 1st all way back up to house with plenty black smoke.

Doesn't seem to get any better or worse....just very little power with black smoke (leaving black soot on stones in driveway when

So have checked all the pipes and air filter (just in case)...all seem ok.

Now I have been researching the forum and elsewhere and as you mention...it seems I have to check EGR, MAF & TURBO (TURBO bit scares me).

Can anybody describe or show me with a photo where these are located?

Oh and forgot to mention - no warning lights etc on dash.
I'm learning as I go but I get the feeling they are bolt on parts so if I know the locations I will have a go? I know there are plenty of posts on here regards this but they seem to be chat amongst people with a bit more experience...ie - I'm a bit lost with some of the technical chat.

But I know my way around a socket set and am not thick so if you guys could help me out I will return the favour by writing up a step by step with full photos for the benefit of any other novices like myself.

 

[BikeDoc]

Have a read trough these first...
Turbo
EGR1
EGR2
EGR3
MAF1
MAF2
MAF3

 

[boilermansab]

Just block the egr, takes 15mins tops...cleaning it could take ages especially getting the awkward allen bolts undone!

 

[multiplani]

Finally back online...had computer issues on top of it all...

Anyway - removed and thoroughly cleaned EGR & all pipe work connected to it...

It was a mess...stuck solid with black crap & the pipework was so clogged up there was only a fingers worth of inner diameter.

Running sweet right now...fingers crossed.

Really glad its yet another wee job I have learned anyway.

Blocking the EGR??? Can the kind fella who suggested this maybe explain exactly how...in basic 'idiot proof' terms...just curious for future reference.

I will do as promised asap and upload a step by step for other beginners like myself.

It was a pig to get it out...lost a few sockets down there somewhere and couldn't find them anywhere!!!!

BUT BIG THANKYOU TO EVERYONE WHO HELPED...I COULD NOT HAVE DONE IT OTHERWISE...SERIOUSLY!!!

 

[slobo]

Search and there are loads of threads on here how to block an egr.

 

[BikeDoc]

Blanking your EGR

Basically two options;
1. Fit 'solid' Gaskets in place of the originals.
Use the original Gaskets as templates to make your solid ones, you can use any thin Metal for them. The outer shape is unimportant (as long as they're not overly large), just get the hole spacing correct and they'll be fine.
If you can, make them like this...

Then you only need loosen the Screws a couple of turns and then slip them into place.

2. Remove the 'concertina' Pipe and fit blanking plates over the Ports.
EGR Blanking Plates...

 

[widemouthfrog]

Re: Blanking your EGR

If you don't fancy making one yourself, lots of people are selling them on ebay for £3-4, delivered. I think I bought my 2mm thick aluminium one from 'bertye1958'. He had loads of different ones listed. It was easy enough to fit even though it didn't have the slots like BD shows.

 

[BikeDoc]

Blanking your EGR

...It was easy enough to fit even though it didn't have the slots...

I suppose 99 times out of 100, if you can loosen a Bolt/Screw/Nut a couple of turns easily, it'll go rest of the way without a problem.

Always worth putting a little Copaslip or other Anti-Seize product on the threads whenever you remove any fastener that gets hot in use, prevents so much aggro next time

 

[multiplani]

Much appreciated guys.

Yes had spotted a few threads but didn't quite 'get' it.

Thanks for explaining....handy to know.