Complete loss of power

[superclarkey]

2.4 rwd tdci.

Had new fuel filter, oil, air filter ect full service.

Pcm updates from ford (w***)

Done the presure relief valve and vapour tube on rail.

Been totally fine drove hard from low down, always felt like van pulled harder then you pressed the throttle if that makes sense..

Over the last 100miles I was sure it was loosing power, it felt like I was having to push the throttle down harder and harder to get it to go, now it is terrible I used to pull off in 2nd on the flat no problem, now 1st you have you rev it out.
I used to drive between 1500 and 2500rpm max now its 2500 to 4000rpm.

It feels like I pushing the van through water...

Its smoking a bit, black smoke, I noticed if I take the oil cap off it chuffs a bit of smoke out there, you can feel the pulses from the oil filler neck and see some black smoke..

Van idles fine, revs up its slow to rev and sometimes almost feels like it misses.

I've noticed lately the engine started to pink, then in the morning knock and not rev, felt like it missed badly until warm then was fine, I plugged ids into it and no faults at all.

Any ideas, had a new EGR just before I bought the van, it has done 145k its ex-rac

[superclarkey]

I'm convinced its the EGR valve. Would explain the knocking I've been getting.

How long does egr last for?

[superclarkey]

Well I did the fun job of taking the EGR off today, was expecting to find the manifold totally full of sh*t, but it was bone dry and clean, strange so I remove the EGR and nope same, cleanish and not clogged up, moved the piston and back and forth and operated the motor, no problem all worked perfectly, but I noticed something that may be the blame and the reason it failed so quickly.. correct me if I'm wrong but is there meant to be something here, looks like there should be a ball and cap there for the helical drive, looks like its dropped out!!

[superclarkey]

Yeah I was right, there must of been a ball and valve in here, weather it jammed then kicked it out or just failed who knows, I know no one seems interested in my problem but if anyone comes across this thread here are some images for you.

This cost me on trade £234.00 retail was meant to be £330, sod that.

[karl]

for a water cooled egr valve

from the pictures you have supplied looks like the cogs electrical side has failed

correct me if am wrong

[v8dave]

I know no one seems interested in my problem but if anyone comes across this thread here are some images for you.

But we are interested, it's just that you've solved it before a lot of us have read any of the thread.

Very useful pictures and something to look for in future.

[superclarkey]

No everything worked perfect, the motors and gear where fine.

The motor turns the shaft and there is a helical grove to drive it forwards and backwards, there was a ball with a cap that located it to the case so it had some way of moving forward and backwards as it rotated, with it gone it turns but doesn't move in or out, infact it will float.

The van is perfect again now, there are a few codes i need to address.

P251A
U300A
U0073
P1796
U0155

To name a few lol

[ake]

You can ignore p251a cos it's the pto code which always appears!

Thanks for the pictures

[paul2012]

P251A PTO Enable Switch Circuit / Open
U300A Ignition cross check fault
U0073 Control Module Communication Bus "A" Off
P1796 CAN Controller Circuit (Bus off)
U0155 Lost Communication With Instrument Panel Cluster (IPC) Control Module

[ake]

You can ignore all of those faults!

[karl]

simples