No boost, no engine warning light...

[Dananjen]

Hey all,
I haven't been on for a while. Been flat out with work.. Hope everyone is well....
Now, I have done just over 10,000 kilometres in 6 weeks in the patrol (2002 GUII ZD30 engine), travel to work and back to home for various reasons with no major issues. Then, earlier this week returning to my family, all was going well until my 2nd of 3 fuel stops.. I filled the beast with her usual diesel, but when I hit the road again, I had no boost / power and no warning light or engine light come up.

I have drained the fuel filter to check for water and contamination, and there's nothing there, I pulled what fault codes I could, and got 42, 52 and 77.....
I have also sprayed all lines to and from the turbo with soap water to see if there is leaks of any kind and again, nothing....

I need help. I am mechanically minded and can fix anything. But I have no idea when it comes to turbo diesels and faults...

Please help me, I have to drive back to Mount Isa from Muswellbrook on 3rd January and don't have a lot of $$$$ to pay someone to diagnose the issues for me.

[Dananjen]

Hey there boys and girls, here's an update.....

Cleaned MAF sensor, replaced all vacuum lines, replaced fuel filter today and cleaned out intercooler.
Air filter was changed 2000 klm ago, oil and filter change done 2000 klm ago, fresh tank of fuel and I still have the same issue....
Any other ideas ?

[TPC]

Have you checked what those fault codes are?
There is a list on here somewhere.

[macca86]

Turbo died maybe if you have no boost and all the hoses are ok, or is the intercooler broken or cracked? When my turbo died there was no warning lights or noises etc

[Dananjen]

Yes I have checked the codes, they are fuel injection timing control system (77), battery voltage (52), fuel temperature sensor (42)...

[Dananjen]

Have had the intercooler off, and cleaned, no issues there. Had a mechanic mate look at the turbo and he has said no issues there too...

Last night I pulled the throttle body and EGR plumbing apart and the was a little gunk in both, but nothing that I would say be causing any issues...

[Dananjen]

I should mention its ZD30 turbo diesel too

[macca86]

Injectors then I'd think your mechanic should know by now

[Paule]

Sounds like bad fuel to me, but not sure.
Sorry just read that you put fresh fuel in. Does it idle and rev fine in neutral?

[Dananjen]

Hey, idles great in neutral (out of gear being manual).. All revs, and idle haven't changed, just got no boost. Was only 30 litres of fresh fuel, I had just under 1/4 tank when I topped it up

[Paule]

Have you got a boost gauge? Get someone to start your car while you watch your turbo. You should see the actuator arm move up a little bit against the grub screw.

[Dananjen]

No boost gague, yeah I've had some one look at the turbo while I rev the engine... Nothing unusual there.

[Paule]

Your actuator arm probably won't move while reving the engine. But it will when you start your car.

[Dananjen]

The actuator on the bottom of the waste gate attached to the turbo moves when the engine is revved.

[the evil twin]

The actuator on the bottom of the waste gate attached to the turbo moves when the engine is revved.

ZD30's don't have a wastegate.
That actuator adjusts the angle of the vanes.

Sounds like the Fuel Injection Error Codes might be the key to what is wrong

What is confusing is that both those codes should illuminate the CEL

[Dananjen]

Is it normal for a diesel fuel tank to be pressurised, pressure releases similar to a petrol tank that is very low or running on empty. Mine does this at half tank

[Dananjen]

53055

So what's this ?

[the evil twin]

53055

So what's this ?

The actuator for the variable nozzle turbo

From memory it will be relaxed against spring tension when engine is off.
When you start the engine the arm should move until the mechansim hits the grub screw.

If it isn't doing that and only moves when you rev it with no load then it is possible you have a leak in the control hoses/valves.
You might have low vacuum or the control valve could be shagged.
Worst case is the Turbo is cactus but rule out the easy stuff first

[Dananjen]

I have replaced all vacuum lines that I can find from the air box and the ones under the intercooler.... Still no boost

[the evil twin]

Sorry mate, been too long since I sold my ZD30 to be sure what is what now so I'll leave it for someone else to try.
If you have good vacuum, the actuator is Ok and the Control Valve is working then either a) the turbo is screwed or b) the ECU is telling the Turbo not to boost

[Dananjen]

Sorry mate, been too long since I sold my ZD30 to be sure what is what now so I'll leave it for someone else to try.
If you have good vacuum, the actuator is Ok and the Control Valve is working then either a) the turbo is screwed or b) the ECU is telling the Turbo not to boost


Thanks mate, got me lost as to what's happening, being this time of year I'm finding it hard to get someone to help too.

All your comments have been appreciated

[Paule]

Just a bit more on what evil said you can rule out the ecu by using a needle and Dawes valve set up

[mudski]

Try spinning the turbo impeller with your fingers. See if it spins good and there is no play in the shaft.

[Dananjen]

And if it does spin ok ? I have also read about a vacuum boost pump (?). What ever site I was on says its mounted under the intercooler, but I don't appear to have one on my vehicle ?

[Dananjen]

It is also taking a little bit to fire when starting, is this a vacuum or fuel issue, I think it is related to my initial problem

[mudski]

It is also taking a little bit to fire when starting, is this a vacuum or fuel issue, I think it is related to my initial problem

I was thinking if you don't have the dawes and needle valve your boost control solenoid, located under the air intake next to the air box, could be cactus. But if you have trouble starting I would go back to fuel related maybe. Injectors I would look at first.

[Dananjen]

Ok boys and girls, some of you may remember my lack of boost issues. Now I'm back at work I have borrowed the scan tool and found that the MAF sensor is registering as the fault code....
Thank you all for your input and advise, it has been very much appreciated.
I also have a few pics with numbers and percentages that I don't understand... Any help would be great.

Hmmm, now I need to upload pics..... Back in 5