OPEL ZAFIRA 2.0 dti Power Drops: Valve Noise, Turbo, EGR, Injection Pump & Cold Start Issues

Hello, I have already read other posts but I have not found a solution to the problem.
I have an unusual problem, the car sometimes has such power that it presses into the seats and once it runs like a naturally aspirated one. I noticed that when the valves tap louder, it has power, and when the engine runs quietly, it has no power. There was also a problem with starting in frost. The glow plugs are checked and operational.

The car is after:
Injection pump regeneration including replacement of the pump controller with another one,
Turbo regeneration,
Replacing the EGR valve and cleaning the entire intake,
The flow was replaced with a new original,

I don't know if the driver may be the cause. Because it was replaced without placing the pump on the pickup table.

Please, thank you in advance.

Hello. I suggest carrying out a computer diagnosis, reading the fault memory and checking the engine operating parameters.
And the pump was completely regenerated or only the controller was replaced?
Fuel filter checked?

The computer was connected. There are no errors. The plunger, tape and transistor would be replaced in the pump. After some time, the transistor beat again and the pumping operator replaced the entire controller, but without dismantling the pump. The fuel filter was replaced immediately. I also listed the transfers with the crosses. In active diagnosis, which parameters should you pay attention to ??

Pompiarz said something about injectors, but I don't know if he just doesn't want to admit his mistake or is he really right. I have already loaded a lot of money in this car and I do not want to do unnecessary regeneration again.

However, I noticed that after replacing the driver, it started to smoke more by about 2 liters / 100km
Reload the fuel maps somehow ??

It's best to hook up when it loses power and then read errors. It is worth observing all the parameters of the engine's operation, especially the injection angle and dose, and as for the drivers, they usually fall when there is a mechanical failure in the pump. Of course, the main issue is the tightness (efficiency) of the fuel supply system to the pump. And when does the engine run loud or quiet? The sounds change while driving or is it louder or quieter immediately after firing?
If there is no air in the fuel system, the fuel filter is ok and the dragon in the tank is clean, then without a computer and tests, it will not be possible.

Engine sounds change as you drive. When I go and, for example, keep the gas pedal constant uphill, it goes without power and suddenly gets power. if, when changing gear, I go down from the rotation, then the roulette either continues with power or silences again. I have auto-com, but I can connect and read errors. I was running parameters such as the engine temperature boost level, but I can't read if they are normal. After starting the engine, it also shows no errors. The pompous man said that the plunger was already carved. And from what I read, it changes the injection angle, and I think that despite the replacement, it continues to trim.

It seems to me that it promises to be a major overhaul of the pump ... Look if you can in the monitoring of the engine operation values of the injection angle (set and real), switch the view mode to the graph and watch what happens with the values while driving. At idle, the injection angle should be about 5 degrees

I am just thinking about buying another pump, translating this belt and replacing the plunger, but I preferred to ask someone wise first, because it does not look like injections. He doesn't smoke. Maybe this guy on the fender made this pump. On the old driver, until the 2nd transistor was beaten, it was ok.
After replacing the driver, the eggs started, but I considered it a coincidence. I even thought
to give this pump to the pickup table, to download the driver to the pump, but opinions on this topic are divided. ok, I will look for these values and connect the computer tomorrow, we will see what happens according to the suggestions.

And further problems with the VP pump ...
https://www.elektroda.pl/rtvforum/topic3448700.html

Welcome. the injectors are knocking, not the valves. replace map sensor

Exactly, the injectors are responsible for the characteristic sound of the diesel operation. In Opel they can give three kinds of thanks:
- loud, hard - at full injection pressure,
- typical diesel, just like idling - lower injection pressure,
- characteristic thin and high voice - in emergency mode
The boost pressure sensor can be of great importance here, because the controller decides whether to give a large injection dose - which is what you hear after changing the sound of the engine to a harder one. It could be clogged with soot and oil. You can check it on the computer (shows absolute value or atmospheric pressure = 1 bar) by comparing it with the tire pump pressure gauge.
It is worth knowing if the EGR is tight, because it would show less boost pressure and, consequently, a reduction in engine power.
Have you checked the vacuum system and the turbo solenoid as a standard? If you bypass it, the engine will work properly up to a certain RPM range, and an overload error will appear at higher RPMs.
Besides, the basic question is, do you have an old type controller (pump 1 plug) or a new type controller (pump 2 plugs).
A different flow meter is intended for the injection of a new type - much more expensive of course, the engine will choke on the old type flow meter.

As I wrote, the EGR valve is replaced and the entire intake is cleaned, i.e. the intake manifold with throttles and it is tight. The pump has one plug, but the flow was much more expensive, it was put on 0 281 002 428 and I bought a new one. The boost sensor is also cleaned of soot. The only thing that surprises me is that Autocom shows 1 bar on the boost sensor while driving, sometimes it jumps to 2bar, I don't know if the program rounds it like this or if there is something wrong with the sensor. The entire vacuum lines and valves are working because there are no errors. I'm just about to try to skip this valve and check as described. I made a few screens with autocom during the return from Christmas, I will post something from them soon.

Added after 3 [minutes]:

The map sensor was also replaced with no change. I now have one spare.

Added after 8 [minutes]:

Hello friend dare23. I honestly thought about such a modification myself. But there is a problem because, as far as I know, the pump controller controls the entire engine. So the turbo valve and EGR, inclusive ??

Added after 14 [minutes]:

at idle:

Fuel dose, car disassembled from 800 to 4,000. rpm

Topping:

constant speed along the route:

Speeding from gear 1 to gear 3 with silting fuel dose:

Rushing from gear 1-3 with power, a dose of fuel:

Top-up chart:

Hello. I tossed the previous link more as a warning and to get to know the topic of problems with VP pumps better and not to encourage such a modification The pump controller does not control "the entire engine" directly, but it is necessary for the correct operation of all engine accessories - in a nutshell. The boost value of 1 bar when stationary is the correct value because the boost sensor measures the absolute pressure (together with the atmospheric pressure: 1 Bar = 1000 hPa). The indicated 2 bar while driving means that the relative boost pressure is 1 bar, but this is only in theory because in the last picture the graph goes by leaps and bounds which is actually impossible. The pressure should build up quickly as you accelerate with the gas in the floor, but not in a zero-one fashion. And either this parameter is not monitored in the monitoring, or the tester distorts the values or something is actually wrong with the boost sensor ... that is, the topic of boost monitoring is still to be covered. What about the values of the target and actual injection angles? Can you see them in delphi?
BTW. A better interface will be one dedicated to Opel (for example OpCom). Maybe some user of the electrode has one, lives nearby and will help in the diagnosis?

I have just noticed that in autocom I will not see the injection contour, but I have already downloaded the obd2 connector diagram for TECH2. I just need to order parts and even connect to a so-called spider to read this data.

Which year is it that you had a new type flow meter?
Try to install an old type flow meter, but in this case the problem is somewhere else ...

2.0 DTI 2000 Zafira A 101 horses I have been for 2 years but it is not known what the previous owner gave her and what ...

Hello. Can you know how much you paid for the injection pump driver regeneration? Unfortunately for me too. best regards

I gave 2.5 thousand, the plunger tape was replaced and the guy dismantled and assembled the pump himself