Rough running following EGR CHANGE

[rotory]

Hi all,


2004 MK6 TDDI Transit. 2.4
Van had started to loose power on hills. It runs like a dream on the flat and idles like A dream. Idle speed seems a tad low at 750rpm, just the hills it’s not happy with
Following numerous suggestions I changed the EGR control solenoid then the EGR valve( replacement, not new). As soon as I started the engine following the valve change I noticed the white smoke and the engine ran rough as if the timing solenoid had gone.
Why would changing the EGR valve cause this or is it a coincidence. It’s had a new filters etc.

I await with anticipation
Cheers lads

[jumbo 57]

Sounds like the egr is stuck open, it's supposed to be closed until around 1500rpm and beyond, at which point the engine can run ok.

Not an expert though.

[rotory]

Thanks for the reply Jumbo. Initially it had a slight knocking but it got worse, then sounded like a tin of spanners

[jumbo 57]

It would a very unlucky coincidence for anything else to be the issue, although I've never seen or heard a Transit run with a stuck open EGR valve, but I imagine they don't like it.

[jumbo 57]

I had the pump timing solenoid issue, starts fine but very very diesel knocky with a vast reduction in power.

[rotory]

Thanks Jumbo
I had the timing solenoid snag about 3 years ago, had to replace it whilst it was on the drive !.
This problem started as soon as I turned the key after changing the EGR Valve. Prior to that it was smooth except for hill climbing!.

[jumbo 57]

EGR then.

[rotory]

Probably have to fork out for a Ford rip-off one

[jumbo 57]

Probably have to fork out for a Ford rip-off one

Or check the actuation of BOTH of yours first, maybe they need a clean.
Check the poppet valve retracts under vaccum.
Also check the controller is actually releasing the vac at idle, thus closing the valve.


Your right, buy a new one, it only stings for a short while.

[rotory]

Both are spotless, original was cleaned 2 years ago along with manifold, but I’ve had intermittent hill climbing power loss for over a year. So that originally pointed towards the EGR being dodgy. Thought the replacement would have solved it.
When the rain stops I’ll refit the original out of interest.
Cheers

[jumbo 57]

To me that doesn't sound like an EGR problem, if the valve sticks closed your onto a winner overall (apart from an eml light), if it sticks open then it's still fine at speed. (I thought)

I'd be looking at turbo wastegate rod actuation, or an intercooler that may be filling with oil.

Hopefully somebody else chimes in with some knowledge.

[rotory]

I have cleaned the entire system from the air filter to thr manifold including the intercooler and a Turbo, so I’m in a mucking fuddle. I shall try the old one tomorrow and let you know

[rotory]

Plot thickens,
Reinstalled the old EGR and the van started and after a few minutes established itself at idle ( low at 750rpm) with a diesel knock, sounded like an injector was not firing. Initially there was white smoke.
Bled 3 injectors, had difficulty cracking the 2nd one back from the front. (No.3 ?) eventually cracked it but as soon as I start to bleed it the engine stalls !. Lots of black smoke now !. Wondering if the injector has suffered following the rough running after previous egr valve fiasco.

Engine idles 750>800 rpm.
Looks like I’ll have to get a new EGR valve
Martin

[rotory]

I think it was running on 3 and one of them (2nd from front ) caused the stall when I tried to bleed.