Hello everyone,

I'm experiencing an issue with heavy black smoke on my Ford Fiesta 1.6 TDCi 95hp (engine code TZJA), model year 2013 (Euro 5).

📋 Symptoms observed:

Significant black smoke at idle when revving the engine hard.

Noticeable fuel overconsumption (+1 to 1.5 L/100km).

Slight loss of power sensation.

No engine light (MIL) and no active DTCs with FORScan.

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🛠️ Background:

Stage 1 remap performed in 2021 by a professional tuning garage ➔ immediately noticed very heavy black smoke post-remap.

In 2024, I asked the same garage to flash the car back to stock.

Black smoke is still present, although slightly reduced compared to Stage 1.

I seriously suspect that they might have flashed a 1.5 TDCi file (75 or 95 hp) instead of the correct 1.6 TDCi DV6D file.

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🔍 Diagnostics and tests already performed:

New MAF sensor, new MAP sensor, and smoke leak test ➔ all air system checks out fine.

All four injectors replaced (reconditioned and bench-tested).

EGR valve cleaned (ultrasonic bath).

DPF differential pressure OK, no clogging detected.

Unable to perform a static regeneration (FORScan returns "Too Soot Load" error).

ECU file read and analyzed using KESS V2:

DL LINK : https://we.tl/t-BXfmbMZ5F2

MAF Desired extremely low (1–3 g/s, even under heavy acceleration),

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📈 PID Observations from FORScan:

Rail pressure ➔ reaches 1600 bar under full load.

MAP sensor ➔ correct turbo pressure (~210 kPa at 3000 rpm).

No DTCs retrieved during auto-tests or driving sessions.

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❓ Open questions:

Is it possible they accidentally flashed a 1.5 TDCi map onto my 1.6 TDCi engine?

Why is the MAF Desired value so low (1–3 g/s), even without triggering a DTC?

How can I formally confirm whether the calibration actually matches my original 1.6 TDCi setup?

Has anyone else encountered similar black smoke issues without any fault codes on this specific engine?

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Thanks a lot in advance to anyone who can help!
Any experiences or suggestions would be highly appreciated.

Kevin

7 minutes ago, PeZlo said:

I'm experiencing an issue with heavy black smoke on my Ford Fiesta

Are you in the Vatican city by chance ? 😉

25 minutes ago, unofix said:

Are you in the Vatican city by chance ? 😉

Hello, i'm from France , in the south 🫣

Someone can share stock map ecd17c70 DA6A-12A650-NC O 281 031 531 ?

 

I can't find on internet. With the stock map I will be able to compare with mine. 

Cordialy