bullet proof except for the gearboxes which are constructed with cardboard and some stickyback plastic.

That's stronger than the cheese used in the construction of the 6 speed boxes at least...

Well the gearbox feels perfect (touch wood)

oooh dear, and expression that goes well with : "how hard could it be" or "watch this"

Mine also sweet as a nut.

I drove an 04 Polo SDI on a 90 mile journey once and it struggled in most situations, quite frustrating at times and overtaking needed careful planning away from dual carriageways & motorways. Quite happy cruising along in 5th gear above 60mph, you don't own an SDI for the 64bhp performance and the 16/17 second 0-60 time - it's all about reliability, MPG & hassle free motoring from the bulletproof engine.

I gave the original clutch and gearbox with 125k on a good run for my money, thought many times this is gonna break and never did... Pulling sprinter vans off ramps etc....

Okay so I disconnected hose on egr, did not see any difference, no EML. On my way back home on the motorway staying in 5th on flat at 60mph put my foot down took 30 secs from 60-70 mph and didn't want to go anymore and to get it to 60mph on motoway slip road had to hold each gear till 4 and half revs to get to speed.

Got a mechanic friend to come out in it with me and said it is differently something not right. We checked the fuses in the car(inside), and there was not one for engine electronics so we put one in. Test run no difference. Looked at the fuses on top of the battery one of the three looks dodgy as the wire bent towards one end.(Going to replace that tomorrow)

Check fuel filter looks bran new, will change that over the weekend just in case, oil and filter as well. Going to put a diagnostic on it tomorrow see if we get anything. My friend also suggest the CAT might be blocked up?

:'(

Aye a bad cat will do this too. You can get em cheap, or do what I did, and take it off, smash out the insides of it and put it back. Fine in this country for mots

Lofty70 I like your approach on it

Do it! It'll free up a couple horses, even on one with a good cat. I just put a pinch bar up it resting it on the ground and lifted and dropped the cat repeatedly unttil it was all gone, took a while but was free, and gave a good bit of grunt

I will suggest it to my friend about doing the cat lol.

Also manage to get a quick snap of some obd readings, not sure if it helps

I don't think there is any point doing any modifications as there is definitely something wrong.

I did a couple of tests whilst out today on some dual carriageways.

Going up a slight hill accelerating from 60-70 took about 10 seconds. Going up a fairly steep hill I could stay in 5th at 70 with the pedal to the floor.

If its taking 30 seconds to get from 60-70 then something is not right. It's not something small either so not air filter or exhaust (cat would have to be blocked which I've never heard of happening), perhaps could be something like fuel supply, eg fuel pump. Or mechanical like brakes binding.

Edited 4 December, 201213 yr by Dunkuk

Dunkuk thank you for going out of your way. I will test the brakes tonight, i will see if the drums are getting really hot at all. and will see if the front discs are redish/brown which should indicate binding. Will ask my mechanic tonight about the fuel pump. Thank you again.

This could also be a fuel issue. Check all the fuel pipe connections. Could be drawing air in somewhere.

Phil

This could also be a fuel issue. Check all the fuel pipe connections. Could be drawing air in somewhere.

Phil

Thank you phil, not sure if this helps but while on the m40 last night doing 60 i was getting 63mpg average (drops to 20-30mpg on hills :()

Edited 5 December, 201213 yr by banburybeetle

mpg sounds exactly like mine, drops a lot on hills! Averages out ok though (see my fuelly sig below). I would be tempted to try and time a 0-60 run on quiet roads. Might try it myself as I havent done that yet.

Update! Diagnostics, much better than my one said that there is an open circuit, problem with the egr value and one guy said it looks like the emissions is being restricted by the cat. One guy rev it and looked to see what came out, there was no black smoke at all.

Rang the garage where I got it which said they will have it in on sunday.... have to wait and see

If you can give us the fault codes we can help more.

If you can give us the fault codes we can help more.

Hi rwbaldwin i will get the code reader back on when the car back.

So update, the garage has the car they said it could the the clutch and are going to replace that, I don't think it is but I'm not going to complain if they want to replace that

Just spoke to the garage all done they said the pressure plate had gone....... will be picking it up tomorrow morning (fingers crossed)

Cool, hope its all fixed.

I'm getting to like the old school non turbo SDI. I drove my mums turbo diesel a couple of days ago and it was very different, you couldn't accelerate from 25 in 4th gear for example.

I tried seeing what what happen if I let the SDI it drive itself in 5th, it trundles along at about 22mph at idle, quite impressive.

Edited 10 December, 201213 yr by Dunkuk

So I have driven to work in the car (Yayish), the mechanic showed me the pressure plate and the spring bits were not level, The clutch feels really soft and feels as light as a feather to push. On the motorway I hit about 80mph at a push, takes now 15 seconds to go from 60 -70mph, which is better then 30 seconds.

Between junction 11 and 10 on the M40 I was doing 75mph when I hit the incline/hill revs dropped had to drop it down to 4th to stay at 60mph.

will clean the EGR value over the weekend and get a another mechanic opinion to be on the safe side.

Thank you all for your help so far.

I think mine takes about 7 seconds to do 60-70 in 5th, certainly not 15. And 80 top isn't right although I don't know what it should be, I'm getting the cambelt done soon and dont want to risk a top speed run before then!

Hello again Dunkuk, well I got it booked in on Friday with another garage (Not the one where I brought it). I have found today that when I come off the accelerator there is a loud rattle/ knocking, Haven't investigated yet but I think it could be engine mount or subframe?

When I pick the car up yesterday the mechanic said when they first got it there was a knocking sound due to the timing being out by two teeth.

I think I will try undoing the CAT again tonight as I gave up the other night. Also under the car I have 3 exhaust boxes Back box middle one then one right at the front, is the one right at the front the CAT?

Hi, it will probbaly look like this.

http://www.ebay.co.u...=item336f78fe47

The timing belt being out would explain the low power, it would not run right. I suppose this has been fixed now?

I dont know what this would do to the engine having the timing out and running about in the car, perhaps it would get a bit sooty in there? I'ld be tempted to put some redex through it, not sure the best way to do this, I've heard of people putting it into the fuel filter so you get a super concentraded mix. I used to pour it into the spark plug holes on petrol cars but you cant do that on a diesel. To be honest though I dont think redex is going to fix anything that is really wrong unless there is so much carbon its stopping the valves sealing or something.

There is a lot of talk of cleaning out EGR valves, I've never done this so I can't comment but it would be worth researching.

There is a thing called a dogbone mount that stops the engine moving forward and backwards. Its easy to see under the car. Right in the middle connecting the back of the gearbox to the chassis. You can apparantly judge this by looking at the engine whilst moving off / rocking the car with the handbrake on or probably just reving the engine, or perhaps even pushing the engine about with your hands if its just you (with the engine off!)

Edited 12 December, 201213 yr by Dunkuk