mk6 2.4 tddi 125ps low power

[haadee]

Thanks for great replies,
I will check if the turbo is the right one, it looks well old so possibly still the original item.

When I drive I sometimes do hear a whistling noise, that was the reason I checked the boost hoses.
My van is an early one, may 2003.
I will see if I can find any cracks in manifold when its running.
When I removed the manifold a year ago for cleaning it out, I did not see any obvious big cracks.

[haadee]

Can't see any very greasy/dirty places where manifold bolts to the head.

Checked turbo its marked 125xx

[Jim Archer]

The manifolds split along the welded joint on the sides of the runners - or at least mine did.

Jim

[haadee]

Is there an easy way to check this, withouth removing the manifold?
Like spray soapy water or something like this on the manifold and see if it bubbles?

[davyjcb]

An inlet manifold won't blow bubbles when idling as the turbo is inactive and the engine has to draw the air in

[haadee]

Can not find any leaks in the hoses, or any obvious signs of inlet manifold cracked.
When I drive the van and floor it, I do hear a whistling noise coming from left front area.
This has been like this since I have the van, about a year.
Intercooler looks in really mint condition to.

I don't really know what I can check anymore?
Also when looking at the wastegate actuator, the hose is directly connected to the turbo.
How can they even increase boost pressure with a remap? There are no electrical components there.
They can only add a bit of fuel to map then.
Should I try to adjust the actuator rod?

[Jim Archer]

The boost pressure is controlled by the pot that is ported to the compressor side of the turbo, it just opens a wee bypass valve in the manifold when boost overcomes the closing spring preload. Try shortening the rod a good couple of turns, and see if the manifold pressure rises.

Jim

[haadee]

Update, had finally found some time to try some things out.

Bought and fitted manual boost controller (t-piece thingy of ebay), because wastegate threaded bar was all rusty.
Tried setting it different preloads, eventually without the hose connected, boost pressure did not change (0.6 bar boost).
Found out the wastegate was stuck (rusted?) in position, considering the 170.000kms van has done.
I choose to replace the turbo-manifold-wastegate all in one.

Tested the wastegate opening pressure of new turbo, it is set at 1.0 bar boost.
Fitted the new turbo went out for testing, got Forscan hooked up.
It is still making 0.6 bar max boost, still got the wistling sound when driving flatout.
I guess something leaks when on boost, which is not visible when engine is idling or off.

So I fixed the wastegate issue, it spools up quicker now and MPG has gone up.
However I haven't found the missing top end power.
When I have time again I will try to pressurize the hoses and intercooler to check them somehow for leakage.

[Jim Archer]

Reckon you have a split manifold, 0.6Bar rings a bell when mine went. They are cheap enough new that if it doesn't fix it, you have at least eliminated it.

Put another way, if it hasn't split, it soon will ...

Jim

[scas]

you might have a hole in the intercooler

[martynx]

If manifold is leaking when you put your fingers down low & to the rear of it you'll get an oily / sooty deposit. This is normally visible on the filter etc to the right of the manifold when its leaking. If whole are is dirty degrease the whole are 1st & drive for a while then check.

[karl]

manifold seals that go flush to the cylinder head may be leaking

had a euro 5 do this

not long ago and one of them was split causing lack of power and limp mode

[haadee]

Thanks guys for the replies.
Had the wife keep engine on 3000rpm in neutral, I felt around the inlet and noticed blow by.
It is split/opened up around port 4-5 underside (near fuel pump).

Can they be repaired?
https://www.datona.nl/kunststof-plastic ... fIQAvD_BwE
I have seen this plastic welding kit.
Because if this inlet is split, why wouldn't a replacement inlet do the same within months time if I am unlucky.

Or just buy this one?
Looks same image as the cheap new ones that are on ebay.co.uk
https://www.groothandel-nemeco.nl/winke ... 22134.html

[Jim Archer]

Buy a new one from Ford, the old one has lasted this long. Thought it was fairly reasonable price when I bought mine a few years back.

Jim

[martynx]

Indeed Jim, they must last 18 years & from Ford the integrity may have been improved.