2007 Mondeo Tdci Heavy Black Smoke

[riz325]

hi all

my car is smoking heavily the smoke is pure black when setting off and only last between 1500rpm to 2500 rpm then gets a bit better also when iam going uphill will smoke so much that i cant see behind when i put foot on gas sometimes needs a bit of power just to move the car from standstill i have searched the forum and no one has the same problem

checked all pipes and they are perfect no rips build up good pressure they have been taken off the car one by one

also have changed the intercooler just in case that was the problem but still the same

car has been decated just to see if it makes a differnce but nothing still the same

changed the electric acutator for the turbo aswell just incase it sticks open

turbo spools over no play on the shaft

egr and inlet been cleaned out plus egr has been blanked off using a blank with a hole in it for the euro 4 model

i have noticed a noise from the air box kind of rumble that gets louder i ve checked all hoses from here and have had it of the car to check for splits but nothing

car has recently had new injectors fitted and new clutch flywheel
car is a taxi and has done 160k

any advice would be much appreciated cant drive the car as its to smokey and dangerous for ppl behind me

cheers

[stooge75]

think you'll need a diagnostics reading on that mate.if you say the hoses are A1,have you tested MAF/MAP? unless you get the multimeter out.you'll need to see what kinda readings everythings giving you.

[stevegtuk]

did you take all the hoses off to check them, or just take the air box to turbo hoses off, and then just visually check he other hoses?

[riz325]

Hi all

Thank for the replies the car has been on the formidable software and the codes that come up are

P0404

P0405

P0406

P0409

All to do with the EGR I hav had it off cleaned blanked and put back oniony just have to get a new one and see if that makes a difference

All the pipes have been taken off the car to look for splits then once put back on to check for leaks when the engine is revved everyone of them swelled up when turbo kicked in

It's driving me mad lol

[stevegtuk]

If the problem isnt solved by blanking the egr, then buying a replacement one probably wont cure the smoke, only the fault codes. Id suggest holding fire with the replacement egr till you solve the smoke problem. You may need the money to fix the fault.

Were the new injectors fitted professionaly?

Have you changed the fuel filter and air filter?

If the hoses are swelling it may be worth investing in silicone ones.

[stooge75]

Agree.Hows ur map&maf readings? No leaks at inlet manifold? Hows your boost? think you need some live-data readings. Know any diesel specialists with a good diagnostics kit(IDS/vmm). If the smokes as bad as you say,i'd seriously think of calling in someone before it drives you crazy