Here's One For The Diesel Experts On The Forum

[KUSKUS]

Purchased a Hymer 680B Starline 2.7 manual about 14 months ago, drives very well but I suspected it was a bit down on power. Its supposed to be 157 BHP as standard and it has previously been remapped by 26 BHP to 183 BHP.
The engine was chucking out a lot of black smoke when under load and was very sluggish on steep hills, the longer I owned it the more I was beginning to realise that something didn't seem right.
I started by changing the fuel filter old one looked like it had been there ages, checked the air filter that looked ok, no mice or birds nests found in filter box.
Looking on the internet someone had suggested MAP sensor so replaced sensor next air leaks from turbo hoses all look ok, turbo temperature sensor changed.
Still the same, change the air filter as a matter of course, no change.
I found a chap on an American forum that had a similar problem and had changed the Turbo actuator solenoid valve so ordered a new solenoid valve and Bingo power restored , no smoke and pulls like a train result but and here's the but I am now getting the Turbo surges , a bit like taking your foot on and off the throttle.
Its not severe and doesn't do it all the time, occasionally if you put your foot to the floor you get a rattle through the exhaust.
I have contemplated changing the exhaust as at some time a new stainless tail pipe has been welded to silencer and could be that the weld is restricting the flow of exhaust gases.
So its over to you any ideas on what to try next ?

 

[Spanner]

If it was mine I would have someone with relevant experience read the live data while you drive the van. Perhaps have a word with these people https://www.uniteddiesel.co.uk/

Chris

 

[Landy Andy]

Check intercooler and it’s pipe work if really smoking under acceleration

 

[tonyidle]

If the surging started after the new actuator solenoid was installed that's where I'd look first. Is it sticking for example?

 

[KUSKUS]

Surging started after new actuator solenoid was fitted but prior to that Turbo was not giving full power after it was fitted full power restored.
The old actuator solenoid was definitely faulty.
Very little smoke now that the turbo is working properly.

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[Landy Andy]

Get a standard map on it.

 

[KUSKUS]

Yes colleague of mine suggested that I put the standard Map back on it as he had the same engine in his and it holed a piston while in France !

 

[Otter Spotter]

Time to get it to a garage on the diagnostics kit, if you like tinkering and buying bits they should point you in the right direct to solve your problem.

 

[KUSKUS]

My only problem is finding someone that will look at the MK1 sprinter with appropriate diagnostic equipment .

 

[tacr2man]

It could be that the variable vanes have got clogged up when it was smoking badly , so that the actuator is jerking rather than being progressive .
Italian tune up might help , to decoke the vanes , or might need to dismantle turbo and clean .

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[KUSKUS]

I suppose it wouldn't hurt doing a clean up of the turbo but I have heard of people spraying turbo cleaner direct into turbo whilst the engine is running and blowing up !

 

[EuroTrotters]

Mercedes 2.7 5 Cylinder. I have had a few of those. Bullet proof engine fitted in many cars, including non Mercedes brands.

Never had any issues myself.

sorry I can't help, but I am sure someone will be along.

 

[Otter Spotter]

Just a thought, when were the injectors last replaced or at least cleaned up ?

 

[KUSKUS]

only done 40,000 miles , wouldn't think they need replacing yet ?

 

[chaser]

only done 40,000 miles , wouldn't think they need replacing yet ?

Have you checked if they are leaking , it's a common problem, the holes they are in get all Carboned up and a hell of a job to get out.

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[KUSKUS]

no obvious signs of them leaking.

 

[Raul]

If the solenoid is actuated by vacuum, I would make sure from vacuum take of all the way to solenoid is 100% no cracks, good clips or changed with silicone hose. It’s ok to have a operating solenoid if vacuum can deliver. If vacuum looses pressure, the solenoid will fluctuate.

 

[KUSKUS]

good point , I cut a couple of inches off the end that goes to the turbo actuator as it didnt look to clever, it was perished , Perhaps i would be a good Idea to replace all rubber hose.

 

[gus-lopez]

good point , I cut a couple of inches off the end that goes to the turbo actuator as it didnt look to clever, it was perished , Perhaps i would be a good Idea to replace all rubber hose.

yes.

 

[KUSKUS]

Just ordered some, will let you know how it goes.
Thanks Everyone for your Input.

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[Blue Knight]

It has a significant overfuel problem from your description which used to be common in slightly older diesel lumps, i.e. when a tuner would simply change/increase the fuel pressure - too much fuel and not enough air.

 

[KUSKUS]

It has a significant overfuel problem from your description which used to be common in slightly older diesel lumps, i.e. when a tuner would simply change/increase the fuel pressure - too much fuel and not enough air.

Would that not produce loads of black smoke ?
It's doesn't smoke at all now .

 

[TheBig1]

Sounds like the vehicle has been sat around quite a bit before you got it. I would as a matter of course change all the old hoses. Have seen a few on the vacuum side that actually squeeze shut under load as the perished side walls get pulled in. That plus if the actuator has seized due to coking up, I would clean the turbo whilst I was there

 

[tonyidle]

Surging started after new actuator solenoid was fitted but prior to that Turbo was not giving full power after it was fitted full power restored.
The old actuator solenoid was definitely faulty.
Very little smoke now that the turbo is working properly.

It depends on what the actuator does: it will either operate the waste gate or if the turbo has variable geometry move a set of vanes. Either way if it wasn't doing what it should the over-fuelled exhaust could have clogged the mechanism inside the turbo. An Italian tune or a decent fuel system cleaner should sort it.

 

[KUSKUS]

I have some diesel cleaner in the system now.
I might try giving it a thrash,
I have to do an Italian tune up on the wife's Citroen Picasso once a year , drive it 20 miles at 70 in third , works every time.
Have ordered some Vacuum hose and going to replace it all next week.
It's a variable vane turbo and I think a clean would be a good idea.
Thanks

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[Jamesh]

My only problem is finding someone that will look at the MK1 sprinter with appropriate diagnostic equipment .

Find a classic diesel MB specialist who loves MB diesels and will relish the opportunity to solve it. Any suggestions?

Cheers James

 

[chatteris]

I would try some archoil, maybe a couple of bottles, my smax had a weird fault like accerating in steps and I thought it was variable vanes not moving smoothly, archoil sorted it

 

[Jamesh]

I would try some archoil, maybe a couple of bottles, my smax had a weird fault like accerating in steps and I thought it was variable vanes not moving smoothly, archoil sorted it

Does this stuff really work? For intake? Exhaust and dpf issues?

Cheers James

 

[chesterfield hooligan]

Have you checked if they are leaking , it's a common problem, the holes they are in get all Carboned up and a hell of a job to get out.

We have in the past poured Coca-Cola all over the injectors and left overnight or even a couple of days and it breaks down the carbon, God knows what it does to your insides.

 

[chatteris]

Does this stuff really work? For intake? Exhaust and dpf issues?

Cheers James

it work for me, i think it would take a lot to clean up a carboned up inlet manifold so i would think you are better of spraying something in the throttle body for that or removing and physically cleaning it, so could always remove turbo and clean vanes but worth trying the archoil, its seems quite dear but simple to try

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