Loss of Power - TD5

**Rommel** · 21st July 2010, 10:28 AM

Hi all

I am currently sitting in Kalgoorlie, WA, with a power loss on the Fender 110 Xtreme.

I was on a road trip, from Perth, through to Alice Springs and back, where Bully130 and I did bump into Isuzu110.

The journey was good for the first 2-3 days with no issues to note.

Our trip was via the Great Central Hwy, with the usual corrugations. Day 4 I filled up at Warburton and started to experience a power loss in 5th gear. At first thinking it was the fuel from a remote roadhouse. I carried on struggling to get over 100kph, when previously 110kph+ was quite easy to maintain on nthe graded hwy.

I then put Bully130's nanocom on which indicated an Airflow issue and issue with injector one.

I managed to keep going knowing that a recovery from such a remote area wouldn't be cheap and the fact that we were still cruising at a relatively good pace.

Day 5 we got to the Olga's still no improvement, so I started to investigate the engine and air system for a fix. No joy with anything so continued.

Day 6 got to Curtin Springs Roadhouse and contacted Sutton Motor's in Alice Springs who thought it might be the Mass Air Flow Sensor that was faulty, so put one on order for my arrival on day 8.

I then had 3 full days in Alice Springs to try and remedy the fault.

I first started by chaging the MAF Sensor which made no difference, I then went onto remove the Ambient Air Flow Sensor and cleaned it and the electrical connection, the Manifold Air Pressure sensor, clean the electrical connection for the MAF, none of these made a difference. I also changed the air filter, fuel filter. I further checked the turbo intercooling hose, that the hot air passes through for laminating and bubbling.

During the early days I also noticed a knocking from the exhaust on the cross member of the chassis. My 110 still has the exhaust system that has an addtional muffler at the base of the down pipe. To stop the knocking I then replaced the rubber bush, which again made no difference.

On my return trip, the problem became gradually worse to the point that when I got to Warburton Ithe 110 wouldn't go more than 20kph.

All that was there including an ex REME soldier from the British Army were confussed.

It wass mentioned at this point that a blocked exhaust could cause this problem and I remembered that my exhaust had been knocking all the time.

I then had to be recovered to Kalgoorlie a trip of nearly 1000kms which only cost $300 (phew) I then got into a garage to get it checked out. I did mention the exhaust which the mechanic obviously didn't take onboard.

Well after two days of scratching heads and after removing the exhaust bolts all was well, so I have a new exhaust en route from Perth and the problem even though an airflow issue was purely down to a blockage in the exhaust.

I fortunately have a new exhaust for $200 without the front muffler, so will hopefully avoid the same issue again on road trips.

I did read a previous thread on the same issue, but due to it being from 2004, I thought I would start a new thread and point out that without the outlet the air inlet won't produce enough air to keep going. So not all airflow issues are down to the filter, sensors, turbo

http://www.aulro.com/afvb/technical-...r-problem.html

**Rommel** · 22nd July 2010, 12:50 AM

Update

The exhaust ordered for my Fender didn't fit so the mechanic cut out the front muffler which is part of the cat converter system and welded in a steel pipe in its place. This has worked and I drove the 600+kms back home from Kal this evening.

On looking at the muffler, I noticed it is just a series of wire gauze filters which seem to collect the soot from the cat converter. This over the years has filled up with soot and it looks like the corrugations on the bull dust tracks has loosened it off. This in turn has started to block up the exhaust causing the lack of power. I'm not sure if removing this box will have any adverse effect on the performance of the Td5 or the cat converter.

**stig0000** · 22nd July 2010, 05:49 AM

learn somthing new every day, at least it was sorta simple and nothing major and expensive

**spudboy** · 22nd July 2010, 12:50 PM

Originally Posted by Rommel

...the mechanic cut out the front muffler which is part of the cat converter system and welded in a steel pipe in its place.

Do you mean the big muffler roughly in the middle of the car (say... 1m long x 300 wide)?

I just looked under my 130 (2001 TD5) and can't see any muffler up the front.

Edit: Thanks for the good description/story in the original post too.

**Rommel** · 22nd July 2010, 04:02 PM

Originally Posted by spudboy

Do you mean the big muffler roughly in the middle of the car (say... 1m long x 300 wide)?

I just looked under my 130 (2001 TD5) and can't see any muffler up the front.

Edit: Thanks for the good description/story in the original post too.

Hi Spudboy

Bully130 doesn't have it on his 130 either. at the front end of the exhaust directly below the down pipe is where mine was. This is for the cat converter so yours may not have it. I think it was a mod for Fenders later than your own. But if you only have the one nearer the back then thats ok.

It only became a problem when it was bouncing of the cross member of my chassis on the corrugations, otherwise it will still be going with it fitted.

Rom

**woko** · 22nd July 2010, 05:00 PM

The diesel particulate filters block up all the time. I have changed heaps of them. Removing it wont have any effect on engine it just wont meet emission standards. But if you have removed the EGR valve like so many people have it wont pass them any way.

**akelly** · 22nd July 2010, 07:42 PM

I may have missed it, but did you check the intercooler hoses? That is a common cause of power loss, the hoses get soft and collapse (suck in) when you put your foot down.

cheers,

Adam

**John W** · 22nd July 2010, 08:39 PM

Originally Posted by akelly

I may have missed it, but did you check the intercooler hoses? That is a common cause of power loss, the hoses get soft and collapse (suck in) when you put your foot down.

cheers,

Adam

How does that work. I thought the idea of a turbo was to pump air through the intercooler to the intake at above atmospheric pressure so if the hoses are soft they will bulge out not suck in? I have had trouble with hoses blown off not sucked in.

**spudboy** · 22nd July 2010, 09:33 PM

I think the internals de-laminate and block the flow. Those hoses to/from the intercooler will be under pressure, so they shouldn't collapse.

I guess the hose before the turbo could collapse though.....

**Rommel** · 22nd July 2010, 11:38 PM

Originally Posted by akelly

I may have missed it, but did you check the intercooler hoses? That is a common cause of power loss, the hoses get soft and collapse (suck in) when you put your foot down.

cheers,

Adam

Yes I did mate, it was soft but hasn't bubbled or de-laminated. I have seen the inside of a de-laminated intercooler hose that sits directly below the turbo

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