Black smoke, No power, No codes D5 E3 163 215k xc70

[alvislacitis]

Hi.

Got this gremlin in my D5 120kW 163bhp Euro3 auto 215k miles (xc70) where there are black smoke, no power, no codes and wont rev past 2500rpm also has very noticable ticking noise. Struggle to start when warm but ok when cold. Happened after i hit speed bump (not sure if relevant or not) Also had camshaft error when this first happened.


Troubleshooting done so far are as follows:

1. New camshaft sensor (cleared the code)
2. MAF readings within values (49-57 kg/h)
3. Fuel rail pressure within values
4. New fuel filter
5. Last x3 tanks had Shell premium diesel
6. Anything EGR related been eliminated by Vdash D5T5 Stage 1 EGR OFF
7. New MAP sensor
8. Intercooler smoke pressure tested no leaks
9. Intake smoke pressure tested no leaks
10. Exhaust removed from Turbo hot side to eliminate cat blockage (cat clean)
11. Injector leak back test between 6ml-10ml on warm engine
12. Injectors when disconnected engine splutters/dies (which indicates to me electromagnet switch works
13. Injector tips stripped and cleaned in sonic bath (spray pattern smooth)
14. Injectors reseated
15. Cylinder compression 350psi
16. Vacuum system new lines also new VNT
17. Turbo actuator moves when vacuum applied also moves freely when pushed by hand
18. Engine mounts hold vacuum
19. Timing not jumped
20. Engine loom wiring sleeves are cracked in multiple places especially above intake cover but strands have no damage.
21. Air mass/stroke 490mg/s
22. Air intake clear of obstructions of any kind, no blockages
23. Turbo cartrige spins freely, no exessive movement or any other damage seen
24. No misfire, idles ok

Black smoke tells me overfueling/bad air to fuel mix

Could ticking noise be collapsed lifters or something?!

Just to note, when MAF is disconnected behaviour on engine does not change apart from triggering error code. Replaced with spare MAF unit and it reads same values in Vida also checked voltage in plug and it has 12v #1 pin and 5v#4 pin as per Vida.

When revved (pedal burried in floorboards) for few seconds it triggers Engine Service Required message which on Vida comes up as MAF negative drift which is because it struggles to get air?!

I'm out of my comfort zone on this one.

I can get 120k engine cheap so do i just swap it out?!

[Tjoffroader]

Good luck on finding the problem, air/fuel/breathing problems perhaps. I'm sure someone on here has seen this issue or can help.

[ca2n]

That's a lot of work already done there, I must change commend you.

Perhaps verify that the hose at the turbo compressor inlet is not collapsing (and hence choking the air supply) when the engine is loaded?