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Mk1 2003 loss of power

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Mk1 2003 loss of power

Postby Haughey1973 » Tue Mar 21, 2023 9:42 pm

Hi guys,
I’ve read numerous posts on here covering this subject but I’ll give you the low down and hopefully someone will hopefully point me it the right direction
3 weeks ago out the blue I lost excelleration while driving, lost power and revs but no lights on the dash. Pressing the accelerator but no revs but the car idled ok. Turned of the ignition and back on and all was good. Hasn’t done it again since.
But, 2 weeks ago my van started blowing out white smoke, like a smoke machine and it also suffered significant loss of power. Quickly checking I had lost all coolant.
I since took the van to Pumabuild in Aldridge for them to check for the reason.
They had the van put it on the diagnostic machine and it showed a map sensor fault and also found 2 hoses split. They replaced the 2 hoses and map sensor but it didn’t clear the fault code. So they refitted the old map sensor again.
Changing the hoses has stopped the smoke and stopped the coolant leakage
The van now performs like a van without a turbo. I know the van wasn’t very fast before the fault occurred but you could tell when the turbo kicked in on acceleration before and now nothing very slow on acceleration.
The garage said it’s either the turbo or ecu fault
I’ve already shelled out £300 for diagnostics and 2 pipes and was give the van back.
The 2 options they have given is a new turbo for £450 or ECU anywhere upto £2k. The van ain’t even worth that.
Could really do with a list of where to start looking myself.
Injectors
EGr valve
Turbo
Like I said they changed the map sensor but the van was the same and the fault code didn’t clear so they refitted the old one.
Any help would be appreciated
Haughey1973
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Re: Mk1 2003 loss of power

Postby metalworker0 » Tue Mar 21, 2023 10:45 pm

EGR.
Well its got the old type of EGR ....no new replacements available , or spares or service parts for it ....
Not sure how its serviced ..because no one mentions it , they always go on about the new type of EGR i have this old type on mine ..one day i may be showing how to service it when i get trouble from it.

EGR blanking plate - some time long ago, someone may have installed one of these .....some are very thin and may burn out with passage of time and mileage.

EGR related
On older high mileage engines, the manifold from the EGR ..and intake tract and back of valves get full of hard to remove, what can only described as a sooty carbony oily gunge...they sell tins of spray to remove it .......but there may be too much for it to even make an impact on it

Removal of manifold and EGR the only effective way to clean it ......risky job that involves taking off down pipe , catalyst ......exhaust manifold ..and very hard to get at ..and may involve snapping studs


TURBO

There is a boost hose ..that can split..which would make the turbo not operate . also linkage that seizes
You can pull the intake pipes off and have a look at the state of the turbo vanes for damage and also try to wobble the vanes with your fingers side to side. any side play and its on its way out
.
Injectors
These are old school , and it is possible to disassemble and clean them , although not many people are brave enough to do it, it can be done..there is a youtube video showing a guy taking them apart ..focus or mondeo, cant remember but he explains it well and guides you through .......trouble is i cant find the video

Catalyst
Just after the exhaust manifold ..seen pictures of them blocked !

Exhaust system

with it being 2003 , that age means its possible for the exhaust to fail internally and partially block / impede the flow of gasses

ENGINE GENERAL
if its done a couple of hundred thousand ..may be worn out

all the best.mark
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Re: Mk1 2003 loss of power

Postby Haughey1973 » Tue Mar 21, 2023 11:48 pm

Thanks mark,

I’ve recently replaced the exhaust upto the cat.
The engine has only just covered 100k. Has done very little milage over the last 20 years.
The garage checked the engine and said it was ok with no loss of compression and the head gasket was ok.

I’ll take a look at the egr valve, to see if it has a blanking plate on it.
The garage said a replacement egr valve was available from euro car parts for my model of van for £515 ?
That’s where they got a map sensor from. was a bit annoyed they wanted over £200 to fit one when they are only £80 from euro car parts.
The garage replace 2 hoses, the large ribbed one that goes to my air filter box.

I was considering replacing the turbo assembly (including manifold) can get a reconditioned one for £180 if I give them my old one. Just want to be sure it’s not something more simple before spending loads of money on parts it doesn’t need.
it’s been to 2 different garages and both said different things. I was hoping taking it to pumabuild (ford performance specialists) that they would be more clued up on repairing it. But to be honest they never gave me any confidence at all had the van 2 weeks and replaced only 2 hoses.
They said turbo or ECU now, then said it may be a simple wire broken somewhere ??
Then charged me £303 for there troubles.
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Re: Mk1 2003 loss of power

Postby metalworker0 » Wed Mar 22, 2023 12:34 am

same as euro car parts brand new egr plus manifold is on ebay for £99

trouble is, it looks a lot different

This is what i think you have on it now

https://www.ebay.co.uk/itm/394432487304?


This is the £99 ebay one, same as same as euro one

https://www.ebay.co.uk/itm/115734013850?

maybe someone else will advice .

all the best.mark
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Re: Mk1 2003 loss of power

Postby Kenton » Thu Mar 23, 2023 8:53 pm

Not a very good service. Saying it could be this, or that, isn't a diagnosis. Personally I would ask for my money back. Then take it to a reputable garage mate. Doesn't sound like the original place knew what they were doing :roll:
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Re: Mk1 2003 loss of power

Postby Haughey1973 » Sun Apr 16, 2023 10:54 pm

Hi guys,
Just a quick update on my nightmare issues with my van
since replacing having the split hoses replaced I’ve been managing to use my van even though still with the power loss until yesterday when I drove to collect my son from his girlfriend 9 miles from my home address.
As I pulled into the cul de sac where she lives, my van started to judder and thick smoke began to bellow out the exhaust
This time the tick over was erratic to the point it cut out, with the engine stopped the smoke continued to bellow out of the exhaust for a few minutes. The van did restart but the idle was erratic and loads of smoke.
unable to drive back conceded defeat and called the AA.
After a 2 hour wait an engineer turned up and proceeded to look at the van.
On starting it he immediately said it was a fuel issue and the smoke it was bellowing out was diesel.
Plugged his diagnostics in and it came up with 2 faults
1. accelerator pedal A circuit defective.
2. Map sensor reading defective.
He reset the faults but both came straight back up.
He advised as a starting point to replace these parts.
He then called a tow truck to transport it back to my home.

I have just ordered a new accelerator pedal & a new map sensor.
He did say if this doesn’t fix the issue to next look at replacing
the EGR valve
Injectors (as one may be over fuelling)
Fingers crossed I can replace the first 2 as this are cheap fixes and it will solve the problem.
Oh yeah he also advised I replace the fuel filter.
If not ? the AA guy has given me a reputable garage local to me to take the van for further investigation with regards the EGR and injectors as these ain’t cheap

I’ll let you know how it goes.
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Re: Mk1 2003 loss of power

Postby Haughey1973 » Tue Apr 18, 2023 6:53 pm

Right replaced the accelerator pedal and fitted a new map sensor and nothing has changed
Still blowing out smoke and erratic idle, when I rev it splutters back to the drawing board :?
Next stop is either the garage or the scrap yard.
Yet to decide :(
I’ll try the garage but if it’s lots more money it’s going to the crusher
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Re: Mk1 2003 loss of power

Postby metalworker0 » Tue Apr 18, 2023 8:59 pm

Is your EGR the old type - you didn't say
..whatever type .a plate can be put in to block off the exhaust re-circulation ..super cheap fix that eliminates any influence of the EGR on engine running.

Does not matter if EGR is not working ..this plate should sort out any problems caused by it.

Here's the search -

NOTE : you choose the right one

eBay listings


link not working

type into ebay :

"transit connect egr plate"

NOTE - Sometimes though ..even if your engine is running right this plate may activate a fault code ,..I've heard that the older type are not effected by the fault code.

As regards scrapping it...i don't know what condition its in .....2003..says to me you want to have a good look to see how much rust is on it, and how much mileage is on it before you spend on it. note a lot of rust can be hidden and concealed on these connects! they rust like crazy...if they have been used in normal manner, left outside ...etc

as a general rule ..if the seam at the bottom is swollen ........its bad within!

all the best.mark
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