Lack of power

[miniman]

Hi folks, how are we all doing?
Whilst driving my 406 110HDi to work this morning, I heard a POP noise from the front somewhere and lost some power. I stopped to have a look, at first thinking that a tyre had punctured. The engine revs up in neutral, but is a bit sluggish and definately running rich cos of the black smoke. There is slightly more whistling noise from the turbo whilst driving, but none more than usual when in neutral with my head under the bonnet.
Any ideas? Turbo pipe leaking perhaps? Intercooler? What should I be looking for? Any weak points in the boost system that fail and give the same symptoms?

Thanks.

[Welly]

Bejesus how the devil are you matey?

Sounds like your intercooler hose has gone, have a looky down at the bottom hose underneath - it can rub on a bracket for the radiator and make a hole (mine went there but made a massive whooshing noise too)

[miniman]

Hows you Welly man!?
Your still driving the same old shite I see!
I still have my old bargain 406. Its done me proud over the years, well until something like this happens. Its done 230,000 miles now and ive only changed the oil once since I got it.

I will get it up on the ramps when I get home and have a better look at it. I did expect it to make more noise than it is if the boost pipework went though.

I do pop in and have a look here when something else falls off or breaks. I love my 406 though, as its put up with some SERIOUS abuse in the last 5 years in my hands.

[Welly]

One oil change in 5 years typical Scottish value-for-money motoring

I remember your car was a steal at the time so you've certainly got your money's worth.

Joking aside, if it is the I/C hose up front then it may have gone because the rear engine mount is shot (mine tore through the eggsauce flexi AND the I/C hose). Not that you'll fix any of that stuff

Nice to hear from you again Sir

[miniman]

After a bit of web digging, I have made up a list of things I reckon on checking:-
Boost hoses- check for splits and leaks
Intercooler- check for leaks
vacuum hoses- check for splits and leaks due to heat stress cracks
EGR valve (needs disconnected anyway even if its ok!)
Fuel filter (can also stop the power due to lack of fuel, and mine has NEVER been changed or even cleaned in the last 5 years) EDIT- Saying that though, the black smoke tells me its running rich due to lack of air, not fuel!
Wiring in engine bay- check for signs of chafing or breaks.

If all else fails, pull the turbo off to clean the vanes etc. (Ive had a bit of a problem with a sticky wastegate for years now but I couldnt be arsed to pull it all apart!)

The dipstick keeps popping up now when I thrash the stones out of it, throwing oil all over the top of the engine. I thought about fitting an oil catchpot to a breather just like we do on the race-cars. The thought was enough though, so I cable-tied the dipstick down and the problem is cured!

She has just obtained another years ticket, so I will keep bodging her until the time comes when I can take the leccy seats out for my Mini and dump the rest.

[Doggy]

Sling the engine acoustic cover in the shed for a bit & see if your dipstick stays put.

[miniman]

Hiya,
I tried removing the cover before, but the dipstick still popped up. Has to be pressurising the crankcase Im afraid. No great worry though, and thanks for the heads up!
I had a better look at the car, and noticed that the bottom hose from the intercooler had a bloody great hole blown in it. That must have been the POP sound I heard. The hole was near the end of the hose, so I cut the offending part (3" of the end) out and joined it back up again to the intercooler.
All fixed, and it cost me bugger all. (my favourite price!)

I may go and clean out the fuel filter yet.
Going to remove the EGR valve too shortly and see what it does.

[Welly]

All fixed, and it cost me bugger all

You really are a jammy git aren't you

Is this the secret to private car ownership? just don't touch the thing, ever

[miniman]

You really are a jammy git aren't you

Is this the secret to private car ownership? just don't touch the thing, ever

Yep, If it aint broke, dont lift the bonnet!!
My poor 406 has a speedo that hasnt worked for years, since I unplugged the ABS pump when the ABS wheel sensors on the back broke due to the backplates being buggered and the springs and clips for the shoes tore the sensors up.
The mpg, cruise control and everything else doesnt work either cos of this.
A few bits of tape over the LED's in the dash fixed that tho, and I guess my speed using the revs! Im pretty good at it now.

Back into the garage now to rip the wifes 306 servo out. I HATE Pugs. Why the hell do I have two of them????? If only everything in life was as reliable as my 1969 Mini Cooper.