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2012 D4D Surging after engine replacement

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  • 2012 D4D Surging after engine replacement

    A question for the brains trust...

    I have a 2012 D4D that has just suffered from the famed cracked piston issue at 174k. Reco engine purchased from reliable supplier and installed by a local mechanic. Injectors were replaced at 134k and according to Techstream are still in spec. New engine runs really well, no abnormal noises and generally performs as it should. No chip or EGT blocking plate in new motor, inlet manifold dipped and cleaned during replcement.

    My issue is it has a surging problem at low revs. First noticed it in low range 4wd holding a constant throttle on a gentle hillclimb just under 2000rpm and the revs would drop off instantly by 400rpm then pick back up again straight away, it does this fairly consistently. It doesn't seem to happen nearly as often over 2000rpm, in fact it is difficult to notice it at higher revs. When driving on the road taking off from a standing start it does it several times - all under 2000rpm. Following my wife driving, the car pulses black smoke each time it does this. When she accelerates flat out there is no smoke at all and it performs as it should.

    I have replaced the Suction Control Valve, and found the MAP sensor filter was blocked so I have temporarily bypassed this and ordered a replacement. I have cleaned the MAF, replaced main fuel filter, secondary filter and tank filter, reset the ECU(battery disconnect for 5 minutes) and still no different.

    I generally dont drive the car often as it is the wifes daily driver, so cannot say with certainty that this wasn't happening before the engine failure, however neither of us noticed it. Obviously every sensor, hose and connector was disconnected for the replacement so there is a chance that something has been missed, but I have had the mechanic look over it again and everything I can see looks okay. No fault codes at all.

    Any advice appreciated, over to you......

  • #2
    Sounds like a PTA!

    Sounds like it only happens during load, any chance it could be a loose connection?
    You said you've had the mech go over it, but might be time to grab a beer and unplug everything one at a time and make sure all the plugs and sockets are in good order

    Good luck with it mate.

    Comment


    • #3
      good also be an earth that isnt connected of loose

      Comment


      • #4
        Have given that my best shot, i did find one plug that wasn't clicked on properly, hoped for the best but no luck. Thanks for the ideas.

        Comment

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