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andrewc2102
Member Since: 08 Oct 2021
Location: Coventry
Posts: 26
  
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Hi all,
I really need some help getting to the bottom of this one as I am flummoxed, and now my MOT has expired and I really need this car on the road.
Some quick details, the car is a 2009 D2 2.7, UK spec so Euro 4 but no DPF.
It recently failed it's MOT on emssision, which for Euro 4 diesels is a measured opacity (smoke test).
I took the vehicle away and ran it with some pre MOT emission reduction addtive and cleaned the map in the inlet Y piece but it still got the exact same reading a few days later.
I've recorded the amount of smoke it's making on a video it's black and only happens at full throttle, to my eyes it really doesn't seem significant at all, but obviously it is enough to fail.
There is no performance or economy reduction whatsover, and no fault codes at all (I have an IID tool)
Since then I have inspected all the hoses for splits but found nothing, I then made a homade pressurised inlet smoke tester which I successfully got smoke coming out of the open oil cap so it was working, but with the cap on there are no leaks anywhere so this to me rules out any type of boost leak.
I guess it has to be something to do with fuelling, you can get loads of readings for injectors etc in the IID tool but I don't know what to compare them too.
I could really do with some guidance of what to look at next if anyone has any ideas!
Thanks,
Andrew
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 1st Oct 2023 6:55 pm |
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HairyFool
Member Since: 04 Jan 2023
Location: Essex
Posts: 539
 
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Check the turbo vanes. When the actuator sticks the smoke can be massive under load ( and low power )
Threads on here how to make up a wire tool to operate the actuator and use WD40 to lubricate.
Worked for me although I have my doubts that WD40 is ideal. A visitor from the dark side, my other vehicle is an MG5 EV
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| 1st Oct 2023 7:34 pm |
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andrewc2102
Member Since: 08 Oct 2021
Location: Coventry
Posts: 26
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Thanks I'll have a look into this.
With yours was it obvious that it was seized when you tried to free it off, and was it causing any codes?
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| 1st Oct 2023 9:29 pm |
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HairyFool
Member Since: 04 Jan 2023
Location: Essex
Posts: 539
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Yes it did generate boost pressure codes, the exact ones I cannot be sure of.
I get the impression that the actuator is not that powerful. Once I managed to get the hook in place movement wasn't that hard but I could have knocked it free getting set up
However the movement was a very "metal on metal" feel and as the WD40 hit the right spot it went smooth and very light to pull and push. More importantly it appears to have solved the problem which was most obvious when towing the caravan.
I have also deleted the EGR, the oily deposits in the throttle plenum chamber and both inlet manifolds was something to behold A visitor from the dark side, my other vehicle is an MG5 EV
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| 1st Oct 2023 9:44 pm |
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jenseneverest
Member Since: 12 Jun 2017
Location: somewhere
Posts: 769
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may sound simple but have you changed the air intake filter ?
The test should also be done with the vehicle at operating temperature.
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| 2nd Oct 2023 10:34 am |
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andrewc2102
Member Since: 08 Oct 2021
Location: Coventry
Posts: 26
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So I had a go at moving the turbo actuator this afternoon, kicking myself a bit that I didn't take a video of it first.
It certainly wasn't totally seized, I was able to push it initally find a finger and it moved away, but it didn't seem to spring back espcially well I don't know whether it's supposed to?
Anyway I made the hook tool and gave it a good workout and spray and it's defo nice and free, took a video of it (see link below) after and it's moving nicely when the ignition is turned on, I only wish I did a before video to compare whether it's now moving more 
https://photos.app.goo.gl/8xYu6GewtB7RAKFF7
I have my doubts that this was ever the issue as I never got any performance reduction or codes for boost issues but guess it was worth doing anyway.
Back to square one now, oh and air filter is a 6 month old OEM, still looks like new.
Anyway got any other ideas?
Thanks,
Andrew
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| 2nd Oct 2023 6:23 pm |
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Moo
D3 Decade
Member Since: 13 Aug 2010
Location: Wiltshire
Posts: 13945
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Premium fuel, a fuel additive and a good hard hot run before the test? New Defender L663 110 SE (known as Noddy!)
Sold Volvo XC90 R-Design (known as Basil)
Sold - D4 HSE (Known as Gerty)
No longer the Old Buses original owner 
231,000 miles and counting
05 S manual owned from March 2005
D4 Face lifted
Still original injectors and turbo
V8 Front brakes
BAS Remap, Allisport Intercooler and deCat
EGRs blanked
T-Max split charge
Hanibal Expeedition rack
Prospeed ladder
Duratrac tyres
IID BT
BAS FBH control
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| 3rd Oct 2023 9:14 am |
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andrewc2102
Member Since: 08 Oct 2021
Location: Coventry
Posts: 26
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I probably should have mentioned in the orignal post, I did exactly this ran a pre MOT cleaner through for about 100 miles and retested and got the exact same result.
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| 3rd Oct 2023 10:51 am |
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L319
Member Since: 14 Dec 2013
Location: Herefordshire
Posts: 2080
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I have found that my 'normal' driving does not really get the exhaust system hot enough to clear any residue and the test will end up blowing some black smoke . I now immediately before the test , run the engine until up to temperature, then run it at maximum revs in a low gear, preferably under some load, local hill is useful, to give it a good blow out . This I do with my D3 and more so on my Rover 45 Diesel, both have passed the smoke test well under the limit . This method was advised to me by Rover engineers when the MoT smoke test first came out.
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| 4th Oct 2023 1:21 pm |
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Pete K
Member Since: 15 Jan 2016
Location: GL
Posts: 10378
 
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leaking intercooler? any oily  patches on it. (more than usual!)
Post your injector offset values. Maybe a couple require replacement
Can see a video
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| 4th Oct 2023 5:22 pm |
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