Thread: D2 TD5 down on Power and getting hot (Help Needed)

Hi all,


I need some help to try and diagnose and issue with my 1999 D2 TD5.


It may have been slowly loosing pulling power over time but not sure if it's just because I got use to it after going from the D1. I'm sure it would pull up hills harder but now find I have to down shift more.


The main problem started on a recent forum trip. On the way home towing the camper trailer it's power suddenly dropped off. It would free rev but had no pulling power. Also the temp was now rising on the engine watch dog. I had to drive very easy in lower gears to keep the temp down. At one stage the watch dog hit 95 at the back of the head so I pulled over. I found The heated hose had a little split near the clamp so shortened it and topped up with water. I think this was a cause from the cooling system getting hot and finding a weak spot, not what was causing the engine to get hot in the first place. I managed to limp it home. Thanks to Loanrangie and Rangieman for your help on the way.


Now I have had some time to look over the issue and here is what I have found and done.


On Initial plug in of the NANCOM I had the following faults.


03-07 Air Flow Circuit (intermit)
09-06 EGR Inlet Throttle Open Load (Current)
09-07 EGR Vacuum Modulator Open Load (Current)
10-04 Gearbox/ABS Drive Open Load (Current)
13-06 EGR Inlet Throttle Short Circuit (Intermit)
15-02 High Speed Crank (Current)
22-01 Road Speed Missing.


I cleared all the errors and only the following return:


09-06 EGR Inlet Throttle Open Load (Current)
13-06 EGR Inlet Throttle Short Circuit (Intermit)


I have also had 20.05 EGR Valve Stuck Closed(Logged) and 24.05 EGR Valve Stuck Closed (Current) a couple of time but clear down.


I have removed the EGR setup and fitted a bypass kit so no longer have the EGR fitted.

I Cleaned the MAF and sender in the Airbox and also the sender on the inlet manifold (MAP I Think).

So this is where I'm at now. The 09-06 and 13-06 are still there and it still seems to lack power. I have not been for a long drive to see if it's still getting hot.

Any help or advice would be greatly appreciated

(Also Note: I'm fairly near to diesels so don't know my way around yet.)

Originally Posted by Landover

Thanks for your comments and advice, give me some points to look at.


I have removed all the intercooler hoses and inspected. The one on drivers side looks ok but found the large one on the Pass is very soft as is the short one. The short one also has a bubble on the inside near the turbo entrance so looks like it's delaminating. I have ordered some silicon replacement hoses from Dave at British Car Components (Bit of a shout out there for a forum Vendor).


I also checked the waist gate. I removed the vacuum actuator and the waist gate freely moves about 10mm, is this all it's suppose to move. The Vacuum actuator or what ever it's called takes a lot of force pulling on it to get it to move, is this right.


I look at the turbo spindle and spins freely. If I move the centre pin of the spindle there is a bit of side ways movement, normal or not.


I'll get these parts on when they arrive and assess my next move.

All this sounds about right to me.