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help!

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SteveGoodz:
To my mind the fact that the top intercooler hose expands when you accelerate then there is a partial blockage in the air system somewhere after the end of the top hose ~ from the air flow meter onwards. It sounds like the turbo is boosting the pressure but it can't all get into the engine so it's causing the hose to expand. Is that possible?

Have you removed the AFM and the hose that goes to the inlet manifold and checked it's clear?

stageonesimmo:
Air flow meter, 300 TDi?

How did you remove the EGR - it has electrical and vacuum connections which can screw with things if not dealt with at the time its removed.  Or did you just blank it off and if so, where - at the top hose or at the base of the valve (the best place for a number of reasons). Was everything OK before you removed the EGR?

The reason for me removing my EGR was a flat-spot at 2250 rpm same as yours - thats the point at which the EGR opens, boost drops as a result, flat-spot, simply put.  You arent going to get much boost stood still, if any with a worn turbo so any symptoms you get revving it on the drive outside are not going to be the same as when its actually pulling.  Best bet is to pull the hoses off as suggested and check for splits/delamination (more likely as splits will result in a clear whistling noise), if its all ok, bang it back together making sure the joints are all correctly sealed and try going for a drive to see what its like.

I can give you some ideas for dealing with the vac and electrical side of things later.........

Good luck with it

Guyh2:

--- Quote from: paul.p on January 02, 2008, 16:31:01 ---removed the egr on my 300tdi yesterday, now i've lost power, wont rev over 3000rpm, thought may be dodgy top hose but when checked it just now when rev it out of gear it chucks out black then white smoke and the top hose from intercooler expands? any ideas please??

--- End quote ---

Is the white smoke really acrid - it burns nose & eyes?
If so then check your fuel filters, white smoke like that is usually down to injection timing - most commonly caused by fuel starvation.

paul.p:
its even worse to day, its all back to original, so guess was just sods law that happened at same time as removing the valve, when gets to 2250 rpm its like all power drops off, wont go at all, under that rpm it drives as normal though?? gonna check hoses and fuel filter 2moro, after that i'm clueless on diesels. it fuels just like run out of fuel but it aint, drop the rpm and its ok.....

karlo:
Silly question time, what's the air filter like?

Check for
collapsed turbo hose
blocked intercooler

I had a similar thing on mine turned out to be the air filter although it didn't look that bad!

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