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  #1  
Old 09-08-2019, 09:15 AM
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power loss after prolonged boost

Hey everyone having issues with my 04 3.0d. under prolonged boost periods (22.3psi towing a car trailer or full throttle through 4 to 5 gears) the boost drops of slowly to 16 psi which feels like half power. When the issue starts the mass air flow value stays constant but the fuel rail pressure drops from 1380 ish down to approx. 700 bar. theres a lot of fault codes which keep appearing which i`ll list at the bottom. my injector value read are very similar across all cylinders (230ish) except for no4 it is (0) same with my selective mass adjustment all cylinders are similar except No2 is overcompensating a lot. Not at any time did the car go into limp mode or display a fault on the dash. except for the loss of power there are no other performance issues with the car.
AS far as I know the only deletes are the egr and the exhaust is straight through pipes from the turbo and not sure if it has been flashed or tuned.

fault code 4b90 injector rail monitoring seems to match when the issue arrises the rest seem to happen regardless.
4203-(0101) mass or volume air flow circuit range performance problem.

4ba0 (0113) intake air temperature circuit high input

4507 (0402) Exhaust gas recirculation flow excessive detected

4501 (0401) Exhaust gas recirculation flow insufficient detected

4B10 (1278) Accelerator pedal position sensor1 circuit high

4521 (1296) cooling system malfunction

Im not familiar with these cars at all and are hoping someone who is can unjumble this cluster fark of issues

Any help or direction welcome

Cheers Russ


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Last edited by Gixman05; 09-08-2019 at 09:24 AM. Reason: more info
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  #2  
Old 09-08-2019, 05:08 PM
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Sounds like a big boost leak somewhere... that's as good a good place to start as anywhere. Easier that the next item - the injectors!

Check the intercooler for damage, and all the joints for leaks etc. There's a bunch of seals on the boost system, so disturbing any joint can require seal replacement....
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Old 09-08-2019, 05:30 PM
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The for the reply wpoll.
I`ll see if theres a seal kit for the intake system and try that. Do you have any thoughts on the fault codes, I guess some would be related to the possible boost leak issue. the only codes that come up on torque pro were the egr recirculation and the throttle position. the rest of the codes have only just started to appear after towing a loaded car trailer for the last 6000km. the extra load was to much for the ole girl. moving house at the moment so couldnt have happened at a worse time haha.
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Old 09-08-2019, 06:39 PM
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Wonder if it could be fuel pump ore pressure regulator - total guess, but having "4B10 (1278) Accelerator pedal position sensor1 circuit high" and seeing the fuel pressure cut by half, kind of makes it look like the car knows your foot's still on the gas, but pressure isn't staying high enough at the rail to deliver the "go faster" result.
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Old 09-08-2019, 10:47 PM
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Smile

I initially thought the same thing (fuel pump) or fuel delivery i changed the fuel filter out immediately but made no difference so was thinking then maybe fuel pump. Do you mean the lift pump or the hpfp. Theres so many variables thats why i turned the brains trust. I cant seem to find any seals atm anyway so might try test the fuel circuit pressures etc. Any suggestions while i google that.
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Old 09-09-2019, 06:10 PM
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Just a thought.. perhaps you’re overheating it? Apparently these engines use coolant temp to control egts, so after a long hard boost, maybe it’s self limiting to protect engine. Does the power come back after a cool down period?

Would be interesting to know if 22psi is stock boost pressure too, mine only runs 19-20ish.
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Old 09-09-2019, 06:50 PM
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I have found a few articles about standard boost, it seems to be agreed around the 26psi. Correct me if im wrong. Mine was brought as an unknown so who knows what was done to it. When i get time I'll go through a ll these suggestions. My first trip towing was down to nsw a couple of months ago towing about 2t and never had an issue. Ambient temp never really went above 18degC and i litterally flogged the shit out of the car and never missed a beat. I towed another car the following week up north to qld only sat on 100kph ambient around 25degC no problem. Towing the car trailer back empty at 120kph the problem started. At this stage it doesnt seem to be temp related it was my second thought after blocked fuel filter so done some early morning test @ 18degC and same issue. I think wpoll might be onto it with a boost leak but am having trouble finding seals for the charge pipe system.. although torque pro shows automatic transmission over heat and another transmission unknown fault but inpa doesnt.. basically i think my car is throwing a tantrum cause i made it work so hard haha.
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Old 09-11-2019, 07:12 AM
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Finally found someone to help me get the correct seals of ebay for the charge pipe system. They wont be here until early october and I'm moving house so will have to postpone the witch hunt until then. Ahh the waiting game really sucks. Thx so far
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Old 09-11-2019, 05:14 PM
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Do the vacuum check on the boost control etc. too sometime - easy to do and it might be the issue.

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Old 09-11-2019, 05:55 PM
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I hate to say it, but I don’t think the boost is the issue at all. If you’re losing fuel pressure, you’re losing fuel going into engine, killing the power.. the engine can’t make boost if it isn’t getting fuel. I think the boost drop is a by product of no fuel.

So I guess need to sort the fuel pressure drop.. maybe that regulator? Or high pressure fuel pump dying?
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