Bram Posted December 7, 2020 Share Posted December 7, 2020 I just bought a Ranger 2.5TDI 2004, it is a UK model with right hand steering and the European environment stuff on it: EGR, a vacuum operated butterfly in the inlet and a vacuum line on the inlet manifold that is read by a sensor, and and electronically operated injection pump. It seems the previous owner has messed with the vacuum lines that operate this environmental protection gear. I suspect the lines do not go to the correct nozzles. This is what happens: cold start perfect, runs fine, but after about 5 minutes the enige starts idling very bad, Relay 1 starts rattling on and off, the butterfly opens and closes every now and then, reving it goes well but when returning to idle it tends to stall and it gallops in order to keep itself going. Or stalls. Driving goes fine, normal power etc, just a rather rough diesel sound, but apart from that only idling is a problem. Can anyone help me with the correct connection of the vacuum hoses? Or else have a solution to this problem? Please see attached photos for current layout of the lines. The main vacuum line connects to the inlet of Relay 1, and the inlet of Relay 4. Relay 4 out goes to the butterfly. Relay 1 out goes to Relay 2 out. Relay 2 out goes to Relay 3 in. Relay 3 out goes to the EGR valve. The vacuum line on the inlet manifold goes to the sensor on the relay block, and measures, I believe, the under-pressure in the manifold. On top of the EGR-unit sits sensor 2, which I suppose measures the position of the EGR-valve. Next to the vacuum line connection on the inlet manifold is sensor 1, no idea what that is doing. Maybe measures inlet temp? This whole layout seems rather balloony to me, especially the Relay 1 connecting to Relay 2 to Relay 3. If anyone can help, that would be greatly appreciated. Bram Quote Link to comment Share on other sites More sharing options...
Bram Posted January 4, 2021 Author Share Posted January 4, 2021 Helpful forum this is. Quote Link to comment Share on other sites More sharing options...
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