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Discussion Starter #1
Hi, just joined and have a major problem with my Sedona 2.9 Crdi 2002. When i bought it the only problem it seemed to have was the glowplug lights kept flashing but the car ran fine so i bought it anyway. That was 6 months ago, about 3 months ago while towing my caravan uphill the management light came on, the car made one hell of a racket, loss of power and black smoke came from behind.

Garage said oil was too thin so i did an oil and filter change and it ran fine for a while then about a month ago after filling up with diesel i lost a lot of power, no new lights came on but after i got it home and stopped it it had problems restarting and then when it did it wouldn't go above 2700 revs even in neutral. After doing a lot of checking on here i found out the light flashing could be the 2 wires going to the heaterbox so i checked and 1 had snapped, fixed that and light stays out. Same problem though so i took car to a garage to go on the machine.

Loads of codes came up including one for fuel pressure, one for egr etc but guy then wiped codes and it started fine, rev problem went so i took it for a drive, going uphill same problem as i originally had, ecu light, smoke, lack of power but not the rev problem. Btw if i take my foot of the accelerator the problem stops but light stays on until i restart engine then goes.

Back to garage and computer shows one code p1120 fuel pressure apparently. I asked and there is nothing coming up about the throttle position sensor. Got it home, read up on here again and opened the service panel. Nothing inside but a sender unit though some on here say i should see a diesel pump and filter, not on my car it seems. Also received a egr blanking plate today from ebay.

A few questions if you have time please.
1. Does it seem likely to you to be the fuel problem or egr valve
2. I have changed the filter in the engine compartment, is there any others i should change and where are they, definitely don't seem to be in the tank.
3. How do i blank the egr off.
4. Is there anything else this problem could be.

As i drive it now it starts really bad even if ive driven for an hour and stopped for a minute. That to me seems like fuel or heater, never seen an heater box before but have known heater plugs to cause a similar problem. Once under load the ecu comes on, stays on and if i push the car black smoke from the exhaust and one hell of a noise. Any help is much appreciated. I have taken the service cover off again but all that is there is the sender unit, a small black box with the fuel gauge on it. I'm not great with cars but it looks liike a float so it isnt a filter as far as i can tell.

Also i should have mentioned it used to drive great up to the 2700 revs, no sputtering or anything and was powerful enough even with this problem to tow the caravan. On the flat i could get to 70 in 5th gear but up hills had to change down to 2nd or 3rd as expected. This other problem now though if i press too much on the accelerator once the light comes on the smoke and noise is really bad. It's at the point where if i'm going uphill at say 30 i have to back off the accelerator so much that i've had to go down gears and lost a lot of speed before the top.
 

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Discussion Starter #2
Quick update. Found a thread on here that had a pic of where the plate fitted and figured what the hell and had a go. Put the 3mm plate i bought from ebay between the engine and the gasket then fitted everything back the way it was. Im guessing all the pipework including the small flexible one goes back where it was.

Started the car, smoke came out the back as expected because i read it takes a while for the soot to work through then took it for a spin. First hill i came to i put my foot down, within 50m the ecu light was on again and the car making a very loud noise, smoke was bad too. Unless i've done something wrong with the egr plate then that wasn't the problem. Can't tell if i have more power as i can't hit the throttle. One thing i have noticed is the car is louder than before, maybe a little tappety, is this usual?

Also still looking for what the other problem could be, the wire that i had to reconnect, one of the two that goes to the heater box, i had to do a makeshift job as i didn't have another connector, going to get one tomorrow but since most of the wires are touching im guessing its not that.
 

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07sedona lx 2000 nubira 74 beetle 86 cbr1000 honda 93 harley lowrider 94 trooper 72 scimitar
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483 Posts
black smoke under power is excess fuel
this can be caused by several things
is the air filter clean?
is the turbo working?
is the MAP working, pipework not blocked?
are all the turbo intercooler pipes secure and not leaking?
ttfn glenn
 

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Discussion Starter #4
Thanks for the reply 93, had garage check it out, turns out the injector seals have split and carbon is that bad it is covering 2 injectors completely. They said about £1k but car is only worth £800 so im going to have a go myself. Hoping wyns egr carbon cleaner will help and that i can find a way to get injectors out and seals without buyin specialist tools.
 

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KIA SEDONA 2.9 CRDI L
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Hi had the same problem with mine turned out to be high pressure pump and injectors had to be over hauled all done and running like new again if you take the plunge use a Delphi diesel specialist NOT DEALER as will cost an arm and a leg .this is expensive enough at a specialist but well worth it .one thing to bear in mind is to make sure your injectors come out easy enough mine was a second hand engine with injectors already removed from head .
 

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2008 SpectraSX, 2014 Optima LX,2006 Jeep Liberty, Linux Mint Mate
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How about immersing the carbon'd up ends (only) of the injectors in choke/carburetor cleaner and gently brushing off the carbon? The seals should be available as a replacement part.. I may be wrong as I have only worked on Petrol/Gas fuel injectors but I thought I'd try to help... I have had success with cleaning the injectors before...

Crdi (diesel) engines mentioned on this forum also have had problems with the fuel pumps failing... The P1120 code sounds like the engine is starving for fuel..

I go along with rabbie41...find a good diesel mechanic familiar with the Delphi system.
He may have some tricks up his sleeve to lower the cost.
Dave
 
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