twincamsham wrote:Hello Folks
Just joined the forum,
Thought i may as well since every google search i do leads me here anyway !!
At least like this i discuss online and may help others while sorting my own problems.
Quick outline on my history
Vehicles - transit tddi 2000 mk 6 90PS tipper truck.Vw T5 4 motion remapped, 2.2 dti vauxhall engined Sierra...
Location - Mid France
Profession - Diesel mechanic and Auto Electrician
Renovating an old stone house here so decided buy a tipper truck, was forever on the road ferrying stuff by trailer and i can squeeze 4 tonne in the transit which is very handy,
Its my first transit but i am a diesel mechanic by trade so i did the usual checks and it seemed to be ok,
However im already starting to have problems, The rattle through the gear lever and clutch pedal means the Dual mass flywheel is on the way out, it refused to crank over for me - getting slower and slower even with twin batteries connected so i cleaned the starter out of filings- from the dual mass f/wheel and thats sorted albeit 'pronloged' the problem, (That flywheel is quite a job so im in no hurry do it)
The gearbox can be dropped in less than an hour it really isnt that bad, worst thing is if captive bolts at the front or captive nut at the back move in the chassis for the engine bed, but front bolts can be tacked back and you can get into the chassis ok for the rear nuts
Modifications to date and problems...
Iv fitted spots and elctric windows from a 99 escort that i sent to the scrappers last week, also a neat single din stero conversion was put in to replace the dead original unit thanks to ebay.
I cut the egr valve clean out of the inlet tract as it had near halfed the passage way with carbon- i did not unplug the valve or burst the diaphram so all is as OEM bar it is missing the rod passing through and a blanking plate installed. ( the ECU does not know and there is not a vacuum leak )
These egr position sensors are common for failing and putting them into limp mode, a resistor to replace it would be a better idea, also the head inlet ports and intake manifold will be just as bad so worth cleaning them out
I also tested the boost and its blowing 0.7 bar which is nothing, i wound the wastegate as far as it would go closed and it improved slightly but its still very much a low blow, this engine is 17.5 -1 compression so in my books it doesnt need protection with such a small turbo it needs all it can get
Should be 19bar compression adjusting the waste gate wont help as if there is over boost the fuel is cut by pm anyway, im sure people have experimented and not been able to increase boost succsesfully. only way is mapping i think
My main problem that hopefully someone can help on is this.
When i start the van - it fires up enthusiastically then cuts out near right away, the only way i can avoid this is to catch the revs and hold it at say 1500 rpm until it gets some heat in the system, after a while i can let it idle- but even full lock of the power steering will stall it- its also lumpy and hunting , Fuel filter and all others have been replaced, it does not appear to be sucking air into the system anywhere. after approx 3 mins running all is normal - no cutting out and will start right away,
There is also no excessive smoke of any colour on startup but it does irratate your eyes so it would not seem too lean..
With the DMF failing it could be causing the crank sensor to play up, as all the metal bits stick to it, but with you saying diesel smoke and running lumpy it could be injectors failing, which is normally only when the fuel pumps start to break down, which then cause bore wash or crack the pistons. I would do a fuel return sample check for swarf. Just run the fuel from return of pump into container before filter housing and block the return connection on left rear of housing to stop the air being drawn straight in and airlocking.
With the normal DI diesel knock its hard to know if the pump is in cold start mode ( advanced )
Only when these sound diesel knocky its when timing is out, or the fuel timing solonoid is faulty (common)
Heater plugs - condition unknown but a friend says their work transit fires up any temperture heated or not heated and my problem lasts several minutes so it kind of rules them out as they only glow red for 20 seconds odd and then shes on her own.
Yes as youll know, a good direct injected diesel should start without heat, they are fitted to the mk6 for emmision reasons unlike the mk5 di that didnt have them, they reduce the extra emmisions that you get when starting a cold diesel engine.
They stay on different time depending on the CHT sensor , then enter after glow period when started to keep the emmissions down.
I would imagine it is down to a temperture sender of sorts as the ECU does not seem to know its cold, yeah cylinder head temp sensor right at rear of head against fire wall they are a nightmare to change.
While cutting the EGR valve out i noticed another small brass sensor in the same inlet tract, it seemed to be a basic air temp sensor of sorts ? it was so covered in carbon theres no way it could have worked. Anyone know what this is ? i took the part number off it. does the ECU use merely the coolant temp sensor to define eng temp - i presume this sensor is different to the temp gauge sensor, maybe its worth changing. There is no conventional air mass meter as i think the TDCI may have.
Yes your right that is a seperate air temp sensor so the PCM knows the density of the air, the type with that seperate sensor is the earlier setup, and the map sensor pipe should be just next to it on the EGR valve, follow the tube and make sure its intact and connect to the MAP sensor. Ive seen a few now were people have messed with the vac tube that operates the EGR valve and this MAP sensor tube and got them mixed up
Later ones like the TDCI also have a combined T-MAP sensor air temp and boost in one.
Anyway i have not done much investiagting due to all the other problems but id like to sort out that start up problem.
The other question i have is should this van be so slow ??
NOt a rocket but not slow at all really.
All though being a chassis cab you may have the 5.77 or something rear diff that actually red lines at 85mph
i know its probably 2.5 tonnes and only 90hp but its like coaxing along something from the 70s era !- i hold all the traffic up even when empty, 50-60 mph is a battle to hold and takes much cog swapping, This is a new generation diesel with double overhead cam 16v with fly by wire injection surely it should be adequate.
Yeah something wrong
Yes the diff ratio is terrible and the double wheels probably dont help but it should still be able hold motorway speeds in this day and age . the accelerator pedal seems to make it louder... but no faster ! To add to all that it likes its diesel too , very much so, usually you get power and high consumption or gutless and a miser on fuel, this thing is gutless and a pig on fuel.
Even if the diff ratio was that bad i would have thought id be able pull like a train in 5th but it often runs out of puff for 5th gear.
Yeah as above prob the 5.77 diff would benefit the 5.16 diff, to keep the pulling right rather than going to the 4.63, these ratios are roughly right but prob not exact
in comparisom to the Transporter T5 PD of same eng capacity i would say there is maybe ten times less power in the tddi, ok there not in the same level of engineering or price but this cant be normal performance or is it ? With a two ton trailer on the T5 i can accelerate at more or less the same rate,can just hear everything working much harder,
As with any vehicle it all depends what the engine is pushing out they all have differnt power outputs for same engines.
If i wanted to go fast id buy a sports car but torque there to pull the load to motorway speeds would be nice for my 5 grand cash
Just a thought with it being a 2000 model it could possibly be a 75ps, check your reg here http://www.fordetis.co.uk
check engine lights come on with ignition and goes out accordingly on startup- if i drive the absolute bo**ocks out of it through every gear- at high revs in perhaps 3rd it will make the alternator belt momentarily screech like a kickback and suddenly the glow plug light will flash and it looses a little more power... key off and on again takes the light off.
Hmmm thats not right, there should be something stored on PCM.
Therfore i have never had it on a fault reader, no doubt there are some lodged but according to the light nothing active, you would think with this performance it would be a fair obvious fault. maybe im expecting too much from it and all is ok.
No not always there is a few things it could be without being blatently obvious
A friend in france here has a FWD 85/280 Transit which i think is the 2.0 tddi , we ferryied a load of firewood each last week and it seemed he was waiting for me all the time on the road and i should prob have had more power than him, i was crawling along and the timber was dry and not super heavy.
The FWD 2.0's are better for performance
I thought of tuning boxing it, but id rather see what its like as standard first - (That is if it is not running as standard now )
Best having it totally right first, then you could get an economy remap far better than any tuning box http://www.vantuner.com
I can hear the turbo spin up and is boosting, I would have thought if the timing was out it would need to be a full tooth out on the chain which would make it run terrible all the time if run at all, is it worth checking timing or anything..
You shouldnt really here the turbo, you maybe have a split turbo pipe, intake manifold or intercooler.
Yes its defo worth checking the timing and getting a new timing chain tensioner but search which one as ford have cocked up on these there only £50 quid just treat it as a timing belt change.
The inlet or crank could easily be out and you wouldnt notice the slight different engine tone
What do people with experiece of transits think of this performance normal or not?
I like the way it drives and handles, its not a rust box and is very useful, but the grunt is really lacking and shamful when even the big Euro 5 artic trucks have to sit behind to wait and oppurtuity to overtake me on the B roads!
few other questions .
If i can source an instrument panel with a rev counter in a breakers yard will it plug right into my loom and rev counter work - (Its not the digital dash version and i have no rev counter at present )
The digi one wont plug in and the ones of your year with rev counter are hard to get hold of, but they can be fiitted from a mondeo diesel if you search it youll see.
Would the 6 speed gearbox from the newer 140 hp transit fit to the tddi engine, as far as i know the tdci is same block so thats probably a yes, Has anyone gone to the trouble to source and fit a 6 speed ? are both 5th and 6th 'overdrive' ratios - eg turn faster than the crank shaft
You need the correct lower ratio diffs to work correctly, changing your diff would be the best route..
Is a diff with a decent ratio hard to locate, i think a twin axle box van with a 4.6 is what i need to replace my 5.8 ?
I as i said above im just going through replying as i go.
Is a tuning box worth doing - Have people tried a DIY attempt with resistors which is what most tuning boxs are.
I have been told the tddi responds well to tuning- better than the tdci. i can't see the point in mapping this truck at present as its not even adequate now and its a lot of money to take a chance on.
As above cheaper, easier and a lot more benefical going with http://www.vantuner.com
final question while im at it, the tipper lift cyclinder is leaking hyd oil around the neck seal on the ram, i suppose there was not one particular ram kit used on all transits as its not a factory thing and it would depend on the maker of the cylnder ?
the yellow electric control is made by SPX fluid power solutions if that gives any clues, I want to try get a kit to rebuild the cyclinder if poss.
Sorry for too much information but it can be better supply a lot to cut out the guessers with not a lot of hands on knowledge!
Not sure on any of the hydraulics
Thanks in advance and sleep happy in the knowledge that you have MUCH more power than me !!