I'm not a mechanic so I'm not sure what you mean by "over run "
Inter cooler hose burst and replaced (my mechanic thought that oil in the hose hase rotted the rubber) (152K Miles on clock) ran perfectly up to the hose bursting
The symptoms are a hesittant or jerky acceleration (Like an elastic band) from 0 - 30mph above this speed no noticeable problem plenty of power
Tickover is sweet as a nut according to an ex mechanic friend (pre Electronic Mechanic)
Occasionally a lag of power and a puff of black smoke
When climbing a steep hill a I get the smoke for a brief moment
Also I forgot to mention earlier with the window down I noticed a Hissing Noise from the engine when under load (sounds Like an Air line Hiss)
The intercooler hoses are oil-proof, so they shouldn't have rotted. If you can still hear a hiss; you've still got a leak somewhere.
This will need looking at by a diagnostics specialist as it's an unusual fault that could well be the air-flow [MAF] sensor or a sticking boost pressure sensor. The extensive live-data available from these systems will determine which; but only in experienced hands.
I'm assuming that your engine is a 130PS PD type diesel, in which case how was the "pump" cleaned? - there isn't one other than the tandem fuel feed pump. Injector trouble on these engines is very unusual and there are not many test fixtures around which will take them.
Assuming it's a PD, there is a quick but not foolproof way of testing the EGR valve - assuming your car has a manual gearbox; the autos are different.
Showing through the engine top cover is the "silver" dome of the EGR actuator with a rubber pipe attached. With the engine off, disconnect this pipe - push it off with a screwdriver, dont try pulling it on an old engine. Now connect a short piece of suitable hose to the stub and suck.
You have to suck quite hard as the spring is strong, but you will be aware of the EGR valve opening as you suck. Hold it open by putting your tongue over the end of the pipe, and check that the vacuum is held. Release the vacuum, and you should hear the valve shut smartly with a soft "click". If you can't hear this, it's probably stuck.
Thanks for the info on the EGR Valve my car is an 02 (2002) TDI 130 Highline Estate Manual. not sure if it's a 130PS PD though ?
My mechanic took the car to a specialist Injector/Pump cleaning firm but not sure how it was done but apparently it was on the machine for about an hour cost £47
Amazingly I located the EGR Diaphram unit as you described and also found a piece of plastic pipe which I managed to fit tightly on the nipple.
Yes ! it responded exactly as you said it would once I had mastered building up a vacuum (6 Sucks) on releasing the vacuum it made a satifying clunk. (Back to the drawing board ?? )
On my way home tonight I called into the mechanic to pay him for my service and announced that I may have found the problem Faulty EGR. He advised me that he had cleaned it and checked it when replacing the Intercooler Hose. He also said the Hissing noise was probably the Dump Valve relieving pressure build up.
I decided to check the symptoms again after leaving his place and confirmed the hessitant acceleration up to 30 mph and on a steep hill climb below 30 mph in traffic a definite flat spot accompanied by a puff of greyish exhaust smoke.
On another hill at above 40mph nice and smooth with no noticable loss of power, I did wind the window down and heard the Loud Airline like Hiss.
I think with all the expertise on this board it's only a matter of time before I find the solution !
Thanks all once again I am very grateful for you help
You were bang, on I asked one of our Mechanics at work to give me his opinion of the fault and he said let's put it on a hydraulic Ramp and wee'll have a look.
After undoing the plastic tray under the engine he showed me a Botched Up hose connection between the rubber and metal pipe !
My Mechanic must have snapped the original taking the old hose off I bought the correct VW Hose Clip on the way home 47p including VAT.
Our company mechanic is going to fit it for me in a week's time when I get back from a hort trip.
I think my mechanic has been the problem all along
I can't believe he would string me along knowing that he had botched the hose job in the first place luckily the last cheque I gave him hasn't hit my account yet
I think a call to my bank tomorrow should sort that out
I have used this guy for well over 10 years and treated him almost as a mate, just goes to show you don't know who you can trust.
I will let you know how the car runs once the correct spring clip is fitted