Help

[skonzo]

I have a 2011 d22 yd25 with major loss of power(struggles to get to 60km/hr) and blows huge amounts of black smoke.
Have replaced the turbo and exhaust manifold which had been cracked. This made no difference. Found cat converter really badly blocked up. Removed internals of the cat and bolted back in place. While still lacking a bit of power was now able to hit 100km/hr, still blowing a fair amount of black smoke but. However after driving only 5km at most lost all power again and blowing a ton of black smoke again. Have cleaned the maf sensor, replaced air and fuel filter but still nothing.
What am I missing, any help would me much muchly appreciated.

 

[MANNING]

Hey @skonzo,
Welcome to the forum.
I would first recommend you scan for codes. After taking note of them - clear them. See if that improves anything and what codes come back. Then you can make your first move

 

[Old.Tony]

Two other things I can think of that aren't too expensive.

Eyeball the hoses of the entire air path from the turbocharger through to the intercooler and then back to the intake manifold. Do you see any black oily emissions? That's the sign of a boost leak.

Your car may not have a, EGR flow sensor and your EGR valve may be faulty. Grab either some 1.6mm mild steel or some 1mm stainless steel, remove the gasket from where the EGR tube connects to the intake on the vehicle right side front of the engine, copy that gasket but obviously without the large centre hole. Fit this and take it for a drive. If it's better, your EGR valve was not working properly and allowing too much EGR in.