No power - 2005 x3 2.0d

[Ozzycat]

Good morning. Can anyone point me in the direction to solving a low power issue with the car. It was off the road for 4 months and then had a new solid flywheel and clutch conversion kit installed. When i got the car back, there was a distinct stuttering/jerkiness at low rpm and no acceleration. Once you got over 2500rpm it took off. Car also loses power going uphill. I cleaned the MAF sensor which removed the jerkiness but still have the low power issue. I used a basic code reader which threw up a P0402 code - Exhaust Gas Recirculation Flow Excessive Detected. I've cleaned the EGR and the problem is still there.
I've got 420,000kms on the motor and while it uses a bit of oil it's still runs well and didn't have this issue before the clutch job. Any advice or direction on where to look would be grateful. Thanks.

 

[getty150]

Could the vanos be gunked with the old oil due to the inactivity you mentioned?

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[Solo Man]

No vanos on that diesel motor. I would make sure that the clamp at the egr housing between that stainless steel housing and pipe is really tight. Then would also clean the sensor situated in the turbo boost pipe leading to the inlet manifold. Would also check for leaks or split boost pipes. When last was the fuel filter replaced? Also disable the egr by removing the vacuum pipe leading to the egr and plug both the pipe and the egr ( a screw or correct size nail works fine. Would be a good idea to remove the swirl flaps on this motor as they are prone to breaking off and flying into the motor!!!

 

[Ozzycat]

Thanks Solo Man for the guidance. Will give that a try. The boost pipe to the egr is one of those preformed plastic housings with a sprung circlip to lock it and seems pretty secure. Would the fuel filter cause low power at low RPM when the car takes off at high RPM? It drives normally but without the acceleration at low RPM.
With the EGR valve, does blanking the pipe and the vacuum line effectively delete it and point to the EGR being the culprit of the poor running. I will be taking off the manifold shortly and was going to remove the flaps and keep the same plugs - saw this on a YouTube as an alternative to using aluminium ones which i would probably have to ship in.

 

[Solo Man]

Your car should have a stainless steel pipe about 25mm diameter coming from the exhaust manifold passing in front of the engine through a square stainless steel water jacket and going into the egr and connected to it with a flange type steel clamp. I think you were talking about the boost pipe leading to the egr. The pipe i am talking about is the 25mm ss pipe with the screw type steel clamp. You can do the swirl flap delete the way you saw on YouTube. Plugging the vacuum pipe to the egr prevents it from opening so efectively disabling it.