200/400/600 Intercooled Common Faults

Symptom: Poor performance, possible hissing noise

Cause: Split intercooler hose


Symptom: Very poor performance feels like no turbo present

Cause: Air line from turbo to MAP sensor disconnected or split


Symptom: Engine performance seems to hold back at full throttle

Causes: Boost cut – ECU reduces the fueling significantly if boost exceeds 19psi for more than a second or two. Reduce boost level and check that pipe from turbo to actuator isn’t leaking.


Symptom: Poor cold starting

Causes: Faulty glow plugs, Faulty glow plug relay, Incorrect fuel pump timing, Air leak in fuel system.


Symptom: Rough running, engine management light illuminated

Causes: Wire to number 1 injector chafed, wires to fuel pump chafed, Blocked fuel filter


Symptom: Diesel leaking or smell from front of engine

Causes: Split/broken/disconnected fuel spill pipes from the injector to the pump


Symptom: No Start following a jump start or removal of battery, possible random display on dash dials.

Cause: ECU very prone to voltage spikes. See page on how to fix it cheaply.

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