Now what?! No power, black smoke... sigh

[sim303]

Ok so 2023-24 is proving to be my Annus Horribilis as far as my cruiser is concerned

Latest problem:

• Barely enough power to pull the skin off a rice pudding (can hardly get up my road (~4-5% grade) at more than 25mph)
• Black smoke
• No DTC
• FSM reference values look reasonable (although it doesn't seem to list what the MAF and MAP values should be. It lists "PIM" but I don't know what that is - is not on my Techstream)
• At idle, EGR system switches ON and OFF every few seconds (FSM says it should be ON)
• E-VRVs (turbo and EGR) and VSV (EGR) check out "ok" according to the FSM
• Vaccum system seems "ok"
• Noticed that live data from the MAF fluctuates between around 0.9 and 1.9 lb/min at steady idle, which seems fishy to me. I'll have to see what the FSM says about the MAF...

My sense is there is no turbo, but I can't prove that until the pressure guage I just ordered arrives.


For info, the original problem, almost a year ago, was a DTC14 code. Since then:

• Fuel check (algae, etc)
• New fuel filter
• Rebuilt injectors
• Valve clearances
• Rebuilt injector pump <--- fixed the DTC14
• Replaced timing belt
• Rebuilt HBB (don't ask), new front brake pipes etc
• Replaced leaking manifold to downpipe gasket

The work above obviously involved removing the intake pipe, cleaning it etc and refitting it, including all the vac pipe, and maybe something has gone wrong there, but if so I'm darned if I can find it.

I don't really understand how there can be no DTC when it's so clearly underperforming, but there you go.


Will update if I make any progress (am not feeling optimistic atm!)


sim

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[sim303]

... with all the recent running problems with the injection pump and fuelling etc, I'm slowly putting 2 and 2 together... (and probably getting 5..)

When I first refitted the new injection pump a few months ago - fixing the original DTC14 problem - all seemed quite ok. Only done a few miles since due to other problems, but did notice a "rushing" sound when applying a lot of power, like the turbo was leaking or something.

Looked into it last week and found soot in the lower right side of the engine bay, and was able to see that at high revs (3000+) the spring joint of the manifold/downpipe was opening up allowing exhaust to escape, causing that rushing sound...

...I assumed the gasket was dying and replaced it a few days ago... the noise has stopped, but the "performance" is absolutely dire

Starting to think I may have a blocked cat.... sigh...

 

[uHu]

...
Starting to think I may have a blocked cat.... sigh...

That's my thought as well

 

[sim303]

Yeah.. I'm having a go at off-car cleaning / flushing of the cat (seeing as it's already toast - nothing to lose). Hopefully will be back on by tomorrow and I'll see if it worked or not.

Very few options for replacement cats (downpipes), as far as I can see Looks like the only options are dealer (vaseline not included) or Amayama.

 

[Jon Wildsmith]

or replace 'cat' with straight through pipe. Not sure how effective that cat is but aftermarket exhausts don't have them.

 

[sim303]

I gladly would, but it would be illegal, given it was fitted from the factory as per the DVLA regs at the time.

 

[Ben Stratford]

A short flexi joint is fairly inexpensive. It might be worth a trial just to identify whether the cat is the issue. Then it could be carried in case the cat gets blocked again?

 

[uHu]

I gladly would, but it would be illegal, given it was fitted from the factory as per the DVLA regs at the time.

Then, as a test, I suggest cutting the pipe just behind the cat and run a long drill bit straight thru a few times, making sure of good flow. That test will tell you if the cat was the problem. Join the pipes with a generic exhaust splice. That's how I got rid of my turbo pressure fault code.

 

[AndycruiserguyLomas]

Not sure how effective that cat is but aftermarket exhausts don't have them.

Yep I have a Cybex 3" in my 100 and it doesn't have a cat in it. It's never been mentioned at MOT time.

 

[AndycruiserguyLomas]

Starting to think I may have a blocked cat.... sigh...

I had the similar problem years ago with my 03 5 spd auto which I had run for a couple of years. With beans there was a definite loss of power and like a blowing exhaust joint. I was busy at the time and stuck it in the barn to come back to, which I haven't yet. When I had the 3" fitted on the latest 100 (110k miles) I saved the original to see, if I ever get time fitting it to my old 100 will cure the problem ( it's been in there 8 years now).
The old 100 had done 200k miles.

 

[Shayne]

A lap around the block with no exhaust might get a few frowns but will do no harm .

 

[sim303]

Thanks guys. When I last wrote, I was part way through a fairly serious back flushing operation of the Cat / downpipe.

I blocked the front end filled it with boiling water, mixed with a LOT of fairy liquid (Max!) ... I let it soak over night, then got the power washer and low-power blasted down the pipe (both directions, several times) using the Karcher power foam car wash thingy. During these steps noticeable amounts of crud came out with each step, some of it quite coarse. Then I flushed with plain water until running clear.

By that time, my 5l tub of Wynns Off-Vehicle DPF Cleaner had arrived, and I once again filled the pipe with the fluid. Plugged up both ends and let it sit overnight, agitating and flipping it from time to time. Flushed it out (very black!) and there was enough left over to do a second round, again overnight. Power flushed again until running really clear, then did my best to dry it with compressed air.

Refitted.

Fixed!


Power is good, very good. For good measure, I chucked a bottle of Archoil 6400D in the tank for a final clean-up. Have done about 100miles so far, all good. The combo of rebuilt injectors and pump, plus the cleared pipes seem to have left it better than before the original DTC 14 arose. Which is nice, given the co$t and time involved!

Pretty impressed by the Wynns too - very benign to use, and seemed to disolve a lot of crap.

Yep I have a Cybex 3" in my 100 and it doesn't have a cat in it. It's never been mentioned at MOT time.

Interesting!

 

[AndycruiserguyLomas]

This is interesting in the fact that the symptoms you had are very similar to what I had on the old 100 series I ran a while back. If I get time soon I might use some Wynns DPF cleaner in the one I took off my latest one and replace the one thats on now. This may pin point the problem I had back then.