Technical Please help! EGR issues!

[acmo]

Hi All!
Had my frog for a few months now with the intention of taking it to the south of france.
True "me" style i have left it to the last minute to get it sorted out before we go on Saturday.
Took it to my local garage today to get fault codes read as it frequently went in to limp mode, the results pointed to the egr and an overboost fault.
Got home whipped off the egr and sure enough it was caked and completely seized. An hour of scraping, turning and a can of WD40 and Carb Cleaner later the valve and solenoid all free and clean.......only the problem now is its flat as a pancake....it will rev out but no where near as pokey as it was.
I dont know how it compares with other multi's but i would say its no where near its alleged 110hp at the mo.
Can any one shed any light?
Cheers
Ben

 

[dave]

have you cleaned boost sensor?

 

[acmo]

Hmmmm no, where is the boost sensor?

 

[dave]

not sure on the 8v, some one should be along soon who knows

 

[T14086]

boost sensor is bolted to back of engine next to EGR, have you tried disconnecting the air flow meter?

 

[acmo]

Great thanks, I will take a look! Have not yet disconnected the air flow, just find it a bit strange that I now how have the egr working and the power is worse than before. maybe its worth scanning again to see if i can clear the egr code.

 

[acmo]

Okay so I disconnected the maf sensor and power was a bit better, still cant get my head around the logic here! I will take a look for the map sensor tomorrow and attack it with some contact cleaner!
Do these have the variable vaine turbo's 2001 JTD 110?

 

[widemouthfrog]

Don't think so - the 1749V turbo is only fitted to the 115. 105 and 110 turbos are fixed geometry. Have a look for a little metal bellows casing sticking out under the turbo.

In my experience, a faulty MAP (aka boost) sensor tends not to flag a fault until you hoof it and the revs hit something over 3k; it then lights up your dash warning and puts you in limp mode (bless it).

Not to do down your hard work cleaning the egr, but have you tried temporarily blanking it to see what effect that has? Easy to do with a bit of tin can and some snips.

 

[acmo]

Based on what you mentioned about the map sensing an overboost that would relate to one of my issues.
The other fault regarding the egr solenoid should be able to be cleared now (fingers crossed) and blanking will bring my power back hopefully!
I will keep you posted
Cheers guys