Poorly pug

[SB118]

Last week my 406TD suddenly started to cough and fart and generally misbehave, no power, no surge when the turbo spins up, rough idle, misfiring, etc. When i put my foot down it looked like a tank doing a smoke dump (top gear - tank vs range rover sport style)

Today i managed to get the inlet and turbo off and i think it's a good guess that the turbo has been breathing more than just air, combination of crappy EGR and the turbo letting go means this snot is inside the head aswell...

I know the inlet is supposed to be slightly textured, but this is taking things too far.

And here it is against the inlet that i'll be replacing it with, from a Xantia without the EGR system

Should have some goodies here tomorrow and i should be back on the road by wednesday

(even in this condition it's a better drive than the wifes corsa )

On the other hand this is the first XUD engined car i've ever had a mechanical failure on, so i can't really moan.

 

[SB118]

EGR = exhaust gas recirculation?

So that means your just putting sooty air back into the engine completely coking it up?

whats the point in that?

It protects the trees and cuddly puppies everywhere.

 

[SB118]

Replacement turbo arrived today, scrapped the clag out of the inlets in the head and washed most of the rest out with a petrol soaked rag.

EGRless turbo and EGRless inlet fitted, engine ran up and STILL smoked. Rolled it out of the workshop and left it running at 2k revs for half an hour (cables ties on the fuel pump makes for a great cruise control ) and the smoke slowly cleared.

Took it for a test drive and it was still missing the extra umph when the turbo spins up, wouldn't rev above 3k (but goes up to 4.5k when reving it at the pump), really struggled on hills.

Decided to sort the busted rear exhaust box and drive the car for a couple of days to see if anything cleared. Couldn't find anything to fit the gap, so we welded in a length of straight pipe
Squirted some carb cleaner into the boost takeoff pipe (the one to the top of the pump) in case some of the snot had jammed the narrow pipe and was causing the underfueling (if the pump doesn't know the engine is boosting, it won't send the extra fuel)

Started it and it STILL smoked a bit. Home time and after about a mile something must have cleared, the engine light went out and BOOM the boost came back and due to the nil back pressure the engine spins up rediculously fast (meaning it will eat what is left of my clutch rather quickly )

But i'm mobile again and loving the increased spin up, it's somewhat grin inducing.

 

[SB118]

Gah, mines diffo the clutch, great in 1st when pulling away, but once i rev it in 2nd the weight of the car is too much and the engine runs away I was showing very slightly when i first got the car, but now it's getting quite bad.