Nissan d22 no power

[dave7840]

The engine on our pickup destroyed its self in march and I finally found time to fit a recon bare engine. Now, it runs fine, idles prefect but it hasn't got any power all the way through the revs. I've check the basics diesel to the pump, fine, no air restriction, turbo appears to chuck out plenty of pressure, held a plate over the outlet, probably not the way to test but hey, Got a mate with the proper diagnostics and no error codes, which kind of leads me to 3 things timing which I triple checked and got two other people two check because it was the one thing I was worried about on my first engine rebuild, injectors which were fine before or the pump which again was fine before. so I rang a specialist test place but they want £60/ hour and said it would take three hours to test the injector pump which I cant believe, so I thought I would ask on hear for any ideas

 

[Lincs Lass]

Diesel filter hasnt got twisted and restricting flow

 

[dave7840]

No, put a new filter on and also checked the tank return flow into a bottle and there's plenty of fuel there

 

[Bruce Almighty]

Our D22 lacked power & engine management light came on so local mechanic took EGR valve of & it was fine ?

 

[agrimax]

Faulty air flow meter,faulty crank position sensor,although would have thought the diagnostics test would have shown this. It might have a micro filter in or below the fuel inlet banjo fitting on the injector pump.Worth looking.Also a faulty neutral position switch on the top of the gearbox can give your symptoms. Sometimes,if you hold the gear lever over to the left when accelerating and the problems goes away,you'll know if it's the cause.Or disconnect it.

 

[dave7840]

Yeah forget to say checked egr

 

[Shovelhands]

Any chance you damaged the intercooler in any way while you had it all apart? Or any of the hoses? A pin hole in an intercooler can cause power loss. Or Manifold gaskets? Anything that has been left disconnected on the manifold, or any plastic fittings that may be cracked or broken?

 

[dave7840]

Faulty air flow meter,faulty crank position sensor,although would have thought the diagnostics test would have shown this. It might have a micro filter in or below the fuel inlet banjo fitting on the injector pump.Worth looking.Also a faulty neutral position switch on the top of the gearbox can give your symptoms. Sometimes,if you hold the gear lever over to the left when accelerating and the problems goes away,you'll know if it's the cause.Or disconnect it.

Had to put a new crank sensor on because I didnt take it off before refitting engine but it didn't show a error code for it. The only sensor on the inlet is one on the intercooler and will have to have a look at that. Fuel I ran a clear hose from the return in to a litre bottle and it filled that in about 15 seconds, so can see it being the problem. The gear box sensor I did see mentioned after a quick search and they all say it only happens in 3 & 4 gears but will try hold the gear lever

 

[mushnt grummmble]

When you say recon bare engine is it on new bearings

 

[dave7840]

Any chance you damaged the intercooler in any way while you had it all apart? Or any of the hoses? A pin hole in an intercooler can cause power loss. Or Manifold gaskets? Anything that has been left disconnected on the manifold, or any plastic fittings that may be cracked or broken?

The intercooler was the first thing out and the last thing in so cant see that it could of got damage but will double check. Inlet manifold gasket was fine

 

[Zetor]

Does it have a boost sensor in or around the inlet manifold, this will tell the Ecu or injector pump to inject more diesel in when the turbo is upto pressure.
Could be faulty or if it's old enough it'll have a small pipe to the injector pump from manifold.

 

[dave7840]

When you say recon bare engine is it on new bearings

When I said bare I meant block crank pistons head and cams all assembled which was supposed to include new bearings

 

[pycoed]

Feel a turbo hose when revving the engine to make sure its boosting OK (unless it has a boost guage that is!)
If you are sure the injection timing is right & fuel is getting thorough OK, then what about the turbo actuator? I don't know if its a variable vane or not, but have a look at the control linkages - some engines have a vacuum modulator & a small split hose there (usually 3-4mm ID) can cause turbo not to boost properly. I've also had one of these fail - not too expensive IIRC about £30.

 

[dave7840]

Does it have a boost sensor in or around the inlet manifold, this will tell the Ecu or injector pump to inject more diesel in when the turbo is upto pressure.
Could be faulty or if it's old enough it'll have a small pipe to the injector pump from manifold.

The only sensor on the inlet is on the intercooler and I don't not want it does, but I haven't looked at it

 

[mushnt grummmble]

When I said bare I meant block crank pistons head and cams all assembled which was supposed to include new bearings

Is it run in then?

 

[dave7840]

Is it run in then?

It ran for about 3 hours. Plus Took to get mot which it went through with only a rear drum sticking which for an 11 year old truck that has been sat to 8 months was good

 

[mushnt grummmble]

It ran for about 3 hours. Plus Took to get mot which it went through with only a rear drum sticking which for an 11 year old truck that has been sat to 8 months was good

A new (rebuilt)engine requires a couple of thousand miles to loosen up

 

[dave7840]

A new (rebuilt)engine requires a couple of thousand miles to loosen up

Its undriveable as is, its that low on power. Took it to the mot on the back roads and you were lucky to get it to 40mph

 

[ARW]

Its undriveable as is, its that low on power. Took it to the mot on the back roads and you were lucky to get it to 40mph

My old one did this an it was a faulty wire to the gear stick. In neutral it shuts down the diesel then when put into gear it lets the injector pump have it. Used to have to drive round holding the gear stick in a certain place. Check that.

 

[dave7840]

My old one did this an it was a faulty wire to the gear stick. In neutral it shuts down the diesel then when put into gear it lets the injector pump have it. Used to have to drive round holding the gear stick in a certain place. Check that.

did it do it in all gears because want ive read, it only happened in gear 3 and 4