W203 lack of power

[fifthwheel]

Hi all, recently bought a c220cdi auto 2004 year w203. Dont think its in limp mode as I can reach 50mph if I wait long enough but is lacking power. My son has a Launch x431 it is showing the following codes.
2136-4 glow plug
2509-2 heater boost control module
2359 charge air system too low boost pressure
1222-1 accelerator pedal sensor signal voltage too high
2626-8 DPF full
I have disconnected the turbo linkage rod, the arm to the vanes is free but the rod wont push back, is there a strong return spring I am pushing against?
I watched the travel of the rod before disconnecting it with some one flooring the pedal but it only moves around 12mm downwards. Can I gut the DPF without a remapp on this car, I cant hear any leakage from the turbo pipes in fact I cant hear the turbo at all, I have a clean exhaust no black smoke. I have a sensor at the back of the airbox with two pipes I suppose this means I have a DPF and cat as opposed to a two cat system. I haven't had the car on a lift yet that's my next job. Sorry for the ramblings any help would be appreciated

 

[Tim203]

I have a T model of the same year without a DPF. I think they only fitted this for a year or two on this model and then reverted back again. I know a guy who has a DPF cleaning system that hangs off the bonnet and doses the engine at intervals while it's left running. It's not a new thing and there are alot of mobile technicians about providing this service. In the late 80,s there was a system called carbon clean for Diesels that I remember being quite effective. My fathers BMW engined 75 with lots of short journeys coupled with probably never being driven over 2500 rpm had the inlet manifold removed to reveal an initial bore of around 2" i.d. reduced to around 3/4". Amazing it ran and the difference was unbelievable when everything was cleaned out.

 

[fifthwheel]

Forgot to say the first thing I did was change the fuel filter.

 

[goach2173]

Don't know anything about cars but a mate of mine had similar problems and I think he said it was the air mass sensor??

 

[BlackC55]

Look at my sticky In the engine section.

 

[fifthwheel]

Thanks for the replies, I have disconnected the turbo pipes and have looked into the turbo intake I can see the impeller turning on tick over. It has too much lift but not enough to touch the housing yet. It does need changing but there will be plenty running around just as bad. The outlet hose is off and even at 3000 rpm (that's all it will rev to) there is hardly any output. The DPF blocked code has now gone, I tried a bottle of DPF cleaner into the tank. I don't seem to have enough fuel being fed to the engine to spin the turbo what could be shutting it down to 300rpm? hence the clean exhaust. If no suggestions I will put it all back together and get a star diagnosis. Forgot to say the turbo vane rod positioner is working fine.

 

[fifthwheel]

Had the car on star today the only thing showing now is turbo underboost and number 4 glowplug. Drove home and took off the turbo, it has a lot of shaft lift but no end float.
It appears starved of oil as if it has restricted oil feed. I am thinking of fitting a new body with my old housings but I have a feeling its not going to solve the problem. I will check the oil feed and return pipes and the flow of oil from the engine block. Will report after the turbo has been rebuilt. I have worked on trucks and plant over the years and have never seen a turbo under performing like this before, they have usually worked until they fail. This engine appears to be starved of fuel.

 

[BlackC55]

Under boost is usually caused by a split boost hose or a turbo actuator fault.

 

[BlackC55]

Look at the top boost hose for splits.

 

[fifthwheel]

Thanks for the replies. I bought a new cartridge from ebay £129-00 delivered. It looks ok but have no idea who made it or from which country. I don't suppose its any where near as good as a Garrett but anyway its fitted now. I cant wait to get it on the road as I have boost back again and am sure it will be ok. The reason I cant try it is I think there is too much oil from the old turbo in the cooler and pipework. I have run the engine with the keeper clip off the pipe at the manifold intake just in case I got a runaway when the engine started drinking the oil. The boost is blowing off the pipe so am thinking of running the engine at max in the morning with the pipe disconnected for a while untill its clear of oil then couple up the pipe and get on the road. We have a big garage compressor with a 3/4 hose I could blow through the pipework and cooler but this would be my last resort as I don't want to pressurize the cooler and make it leak. Will report back.

 

[fifthwheel]

Update, ran the engine this morning with the manifold air feed pipe disconnected at 3000rpm to blow the oil out of the cooler. Got it as clear as it was going to get then put the pipe back on and went for a test drive. Result perfect. Many thanks for the help, great forum.