2.0d manual lack of power low rpm

[Ozzycat]

I eventually got around to changing the clutch on the car after 4 months sitting gathering dust. The car had a new solid flywheel conversion kit installed as well as clutch fork and slave cylinder etc and starts and drives fine for the most part. On starting and low speed its fine. The problem is that there is just no power or acceleration. The car is sluggish and a bit jerky and then takes off again when the revs hit 3000.
Has anyone got any ideas as to what this could be to try narrow it down a bit. It cost a small fortune to do the clutch job and a new battery to boot so funds a bit tight right now.
Any input is welcomed.
Cheers

[X5Sport]

Check that all the vacuum hoses for the turbo have been reconnected if you took any off.

[Ozzycat]

Am i right in saying that there is only one vacuum hose to the turbo. I found a thin hose running from the pressure converter over the intercooler pipe and down into the turbo area but cannot see where it goes to. It appears to be connected as it doesn't come away when pulled on. Its hose 10 in this pic.
What i did find however is that the pipe was badly frayed where it passes over the intercooler pipe but i didn't see any splits in it. If this is the damaged pipe how to i connect it to the turbo when i can't even see where it goes.

hose.JPG (11.76 KiB) Viewed 38237 times

Any tips would be welcomed.
Thanks

[Leslie]

There should be a vacuum valve on the turbo with a rod to the actuator, the vacline just pushes onto that valve., that line needs changed as you are not operating the variable vanes so have no low down boost.

[Ozzycat]

Thanks Leslie. What is the best way to get to this. Do I need to strip out the intercooler pipe etc as I can’t even see the actuator let alone get my hand in anywhere. Thanks.

[Leslie]

Can you have a look from underneath up on ramps ? ,it may provide better access, not familiar with your model so cant advise .

[Ozzycat]

I got round to checking the car and there doesn't appear to be a vacuum leak. I did however take out the MAF sensor and gave it a good spray and clean with Liqui Moly MAF cleaner and this has removed the jerking and hesitation at low revs. I also got hold of a basic ELM 327 reader and set it up with the Carscanner app and it only pulled up two codes -
P0402
Raw code: 0402
ECU: 12
Status: Confirmed
Exhaust gas recirculation (EGR) system - excessive flow detected
Exhaust Gas Recirculation Flow Excessive Detected

============2==============
P3263
Raw code: 3263
ECU: 12
Status: Confirmed

Looking online it seems that the best place to start is to clean the EGR valve for the 0402 code and the P3263 could be the MAF Sensor which has now been cleaned. I've cleared the codes for now so will take it for a drive tomorrow again and re-scan it and see what comes back. The car is way down on power below 2500 rpm and drops off on uphills but once you hit 3000 it pulls like a train.
is there anything else i should be loooking at for now before i go down a rabbit hole of switching out parts.
Thanks.

[Ozzycat]

Bit of an update here. At the weekend i got around to removing the EGR valve and intake manifold and was surprised at how clean they were for a 420,000 km diesel. I have my suspicions that the manifold has been replaced sometime as the swirl flaps were still intact and shiny on one side with little carbon build up. Both had a good cleaning in any case and i left the swirl flaps intact. I also replaced several vacuum lines that appeared suspect - the one to the turbo from the pressure control valve was not easy and it definitely helped to have thin wrists to do this.
Once reassembled, the car would not start and after checking the electric connections it fired up. Performance is better and turbo seems to kick in a bit earlier around 2250 rpm from 2500 and takes off after that. The drop in power on hills has remained the same.
I used a basic ELM327 OBD reader with the Car Scanner app and got the following codes -

4212, 4222, 4232, 4242 - these appear to be glow plug related

4332 - Fuel rail pressure valve

4530 - Charge air pressure control

3FFO - Mass air flow sensor

These were all codes that were never picked up before. The question is where do i start checking / testing from here. Just completed home renovations so don't want to be throwing money at a 20 year old car and i would like to get the car back to proper running order. Any advice or guidance would be appreciated.

Thanks

[X5Sport]

The 4 glow plug errors may also indicate the controller has failed…..but given all of these are new and appear electrical, recheck all of your wiring connections and ground straps. Something got disturbed and is affecting these circuits. The last two are inlet manifold area, the fuel rail pressure sensor is on the common rail itself.