P38A FIP refurbished and refitted - no power and very smokey

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M

Mukiwa

Well-Known Member
Posts
472
Location
Winsford, Cheshire, near Oulton Park
Hi all, finally returned now that the panzer is rolling again.

I finally have my FIP refitted and all back together. Professionally serviced and all gaskets and o rings replaced.
It starts fantastically now compared to the struggle it had before. No diesel or oil leaks now which is good. I went through all the static checks yesterday on my drive all good. The only problem when I went on a short test drive is that I have no power on the kickdown. It does change gear but it pumps out a LOT of black smoke and doesn't really go much faster. Now parked up safely again.

Does the FIP have to be adjusted or calibrated to the engine in any way now?
Thanks all
Hoppy

2.5 DTI bmw. It does have the hot start box fitted and I know that the previous garage "altered" the fueling to mask the hot start problem.
 
Mukiwa said:
Does the FIP have to be adjusted or calibrated to the engine in any way now?

2.5 DTI bmw. It does have the hot start box fitted and I know that the previous garage "altered" the fueling to mask the hot start problem.
Click to expand...

Think you answered your own question .. I dunno the particular model well, but it seems to me a good start would be to return all settings to bog standard and go from there. The altered fuelling is now fuelling way too much ... ;)
 
Hi Paul,
Thanks I do suspect that, my problem is I have no idea how to back the fuelling off hahahaha. Is it mechanically done or will I need a black box to do it? I'll have to read the RAVE manual. I know the garage did alter the fuelling as I had a bit of a tete a tete about how could they have test driven it properly and then handed it back to me when it wouldn't start after it had warmed up and they told me the hotstart box didn't work.
 
Think you better have a talk with the bloke who professionally refurbed your pump. Pump calibration is done on a very expensive machine. Over fueling should not be possible if it has been done correctly. It is not possible to increase fueling on a correctly calibrated EDC pump without chipping the ECU.
 
wammers said:
Think you better have a talk with the bloke who professionally refurbed your pump. Pump calibration is done on a very expensive machine. Over fueling should not be possible if it has been done correctly. It is not possible to increase fueling on a correctly calibrated EDC pump without chipping the ECU.
Click to expand...
And i bet he say's "you need the injectors doing now".:D
 
wammers said:
Think you better have a talk with the bloke who professionally refurbed your pump. Pump calibration is done on a very expensive machine. Over fueling should not be possible if it has been done correctly. It is not possible to increase fueling on a correctly calibrated EDC pump without chipping the ECU.
Click to expand...

That idle 128 value in the Nanocom setting, is it just the idle it affects or will it mess up where the map thinks it is at all ranges?
 
Grrrrrr said:
That idle 128 value in the Nanocom setting, is it just the idle it affects or will it mess up where the map thinks it is at all ranges?
Click to expand...

Only effects idle speed. Comes into operation when idle switch is engaged at less than 9% throttle. Does not effect rest of running map. Having spoken to him i am reasonably confident it is not the pump at fault. He needs a diag read (proper one).
 
Last edited:
N2O said:
Check intake elbow between "intercooled" plastic and turbo.
Click to expand...
That one seems ok, it appears to be the pipe between the intercooler and the intake manifold. It's a bit squashy in the middle and most definitely not round I think I might order replacements for the elbow as well. The one coming from the turbo seems ok
Wammers I may still take you up on the offer of the diagnostic box once I get replacement hoses if that's ok still? I'll even bring you some beer ;)
 
Mukiwa said:
That one seems ok, it appears to be the pipe between the intercooler and the intake manifold. It's a bit squashy in the middle and most definitely not round I think I might order replacements for the elbow as well. The one coming from the turbo seems ok
Wammers I may still take you up on the offer of the diagnostic box once I get replacement hoses if that's ok still? I'll even bring you some beer ;)
Click to expand...

No problem just say when and we can arrange something. Hoses can delaminate internally and block the flow. So you would get boost fuel then a restriction as flow rate increases giving a puff of smoke and power loss as air is restricted.
 
Last edited:
Mukiwa said:
That one seems ok, it appears to be the pipe between the intercooler and the intake manifold. It's a bit squashy in the middle and most definitely not round I think I might order replacements for the elbow as well. The one coming from the turbo seems ok
Wammers I may still take you up on the offer of the diagnostic box once I get replacement hoses if that's ok still? I'll even bring you some beer ;)
Click to expand...

Elbow must be very stiff, newer one is simply plastic instead of rubber in old ones.
Intercooler to manifold pipe can only be bad if delaminated, it cannot be sucked as there is always positive pressure(there will be negative pressure if intake elbow closes first).
 
Pressure drop off as an inverse square when a gas so it will drop off sharply. Would expect something although the turbo doesn't cut in till, what 1750 rpm, maybe?
 
Update:
I have now fitted new MAP and the new intercooler pipes x 3. Definitely an improvement as at least it now goes over 60mph. I got quite a bit over on a test run on an unamed dual carriageway but it does look like a black smoke red arrow display until I ease the revs then the smoke stops. But still does black and smoke once I floor the accelerator.
The air filter doesn't look too dirty. So I'm going to check the air flow through the intercooler next, just in case some wildlife set up a nest over the 4 months it was off the road with hoses disconnected!
 
If I do lots of short journeys and then accelerate hard with a cold engine then it does smoke a bit. Enough to see in the rear-view mirror and make me feel guilty if there is a school nearby. A good motorway run or let it get good and warm and it stops.

Flushed my intercooler at the weekend. Do it fairly regularly.
 
Mukiwa said:
Update:
I have now fitted new MAP and the new intercooler pipes x 3. Definitely an improvement as at least it now goes over 60mph. I got quite a bit over on a test run on an unamed dual carriageway but it does look like a black smoke red arrow display until I ease the revs then the smoke stops. But still does black and smoke once I floor the accelerator.
The air filter doesn't look too dirty. So I'm going to check the air flow through the intercooler next, just in case some wildlife set up a nest over the 4 months it was off the road with hoses disconnected!
Click to expand...

You need some diag on this ASAP see what's going on. You can play with stuff for ages and spend a bloody fortune and not find the problem. Does the MIL lamp ever come on?
 
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