Right here goes,
its my dads friends car , early pre facelift 2004 cdti 150 estate ,he bought it at auction ( see why it was there now .. )
problems are this,
he complained that it smoked a lot - so i looked into it and when i drove it it felt really flat and low on power for a 150 bhp car, heard when accelerating it was forcing air out, originally thought it was boost pipe etc split but was blocked exhaust. Yes you got it blocked dpf, bypassed it by just slipping off exhaust before dpf and drove it - went like stink. So i used my eclipse diag tester and forced a regen to help clear it - no good. later i noticed one of the rubber vacuum tubes off dpf so i replaced it and re connected dpf and forced another regen and to see if driving it helped clear it through , got better but its still asthmatic . checked through service history to find a dpf has been replaced aug last year ( bought car in september i think ) so said not to change it again yet until we got to bottom of problems which caused new dpf to fail so soon.
Things i have done so far,
Stripped out egr cleaned plunger assembly & cleaned up the electric side of egr plunger
replaced vacuum hoses around the front engine area by solenoid
cleaned out boost sensor ( wasnt that sooty to be honest )
Other problems he has is stalling at idle ( i noticed only happens when warm or when temp on dial is at normal operating temp ) and losing power once warm and stalling going along ( happens 3-4 times on me and gets and stops but also hesitates/ misfires circa 2k
Also ifd driven down motorway it goes into limp mode once i use 4th and try to accellerate past 70mph - could that be due to blocked exhaust ? Going to try another motorway blast tomorrow after disconnecting dpf away to eliminate backpressure from dpf causing this fault.
Guess i better look into swirl flaps too...
Can the egr cause this stammering / misfire and stalllling issues? i thought as it was only controlling waste gases it would make it slowly affect the engine rathe than just stall it? Even though i have completly cleaned the egr can it still be faulty?? All the times this happens no management light comes on , only when im down the motorway in another scenario.
Any pointers/ help mucho aprreciated !