OK clever people, what's going on here? Under mild acceleration to redline, all OK, no smoke, engine runs smooth, returns back to good tickover. Give it a fast accelerate to redline, big puff of black smoke and then totally rough running at idle, to the point the whole engine shudders and almost cuts out. Give it a few seconds, idle comes back and ticks over OK. Give it another easy rev to redline, all OK, a hard, fast rev to the redline gives the misfiring, shudder on the engine at tickler and plunges of Black smoke.
When I press the bleed pump on the filter head, it takes 4-5 pumps to get the plunger to go hard after the hard acceleration and rough running issue. Feels like there's air getting into system or the injection pump can't keep up with demand? There's no fuel pump in tank AFAIK, the HP pump is run off the cambelt. Its common rail diesel, so HP to a fuel rail, injectors triggered by ECU and any excess pressure in rail returned to tank.
Néw diesel filter and washers fitted, bled OK, starts on the button hot and cold.
I've also changed the intercooler pipes, from turbo to intercooler and intercooler to throttle body. Have checked the one from airbox to incoming side of turbo as well. Cleaned MAF and MAP sensors and throttle body intake. New air filter fitted. Only thing I can't do is remove and clean EGR valve as its so difficult to get to.
After all the effort I put in to do the welding on both side sills, I'm reluctant to give up on it!
Will do research on EGR valve removal.
Seems odd that it passed emissions ok last year on MOT and has only done 450 miles since then, perhaps sitting around not used not good for it?
BTW,no codes on code reader, so would seem to be a mechanical issue rather than an electronic one?
Any suggestions welcome! Thanks in advance!
Unable to load video here, so posted on Youtube here:
https://youtu.be/mRYKDB0ugVo