Hi,

I've not long had my Fiesta Zetec S 1.6 TDCi. Now the car has had no issues what so ever until I discovered a blue smoke problem. It has FSH and has only done 65431 miles. Now to my amazment the car was serviced by the previous owners garage and I found it had been overfilled with oil (1.2 Litres over). I drained the oil asap, it has reduded the blue smoke immensly but from time to time I am getting a lot of smoke still, I am also finding that it seems to have back pressure as the oil is seeping out in places, including 2 of the injector housings (right at the base).

Now the stuff I have done to try to stop the problem:

Taken off the EGR valve and cleaned (this was dirty).

Turbo Oil pipes off and seem to be flowing.

Now this is where I need help, I want to clean or change the PCV, but I can't find it on this car and I've about pulled all my hair out lol, so can anyone tell me where it is pretty please.

The car runs a dream and is really quiet. From cold purrs, but you can here the engine change tone as it gets warm and it then sounds like it's pressuring.

Now could the turbo seals have gone or PCV, plus the oil they've used is crap, smells and is already going dark. Would cheap oil cause issues to?

Any help would be greatly recieved as the car is mint and to be fair I'm a little gutted.

Thanks Guys :o)

Overfilled by a litre+ no wonder your poor thing is smoking

Blank off the EGR Valve more trouble than they are worth.... no pcv valve

:Remove intercooler and pipes and clean clean clean . eventually the smoke should go

Cheap oil is a definite no no, Quality oil unless you want to kill your turbo etc.

once you have blanked off the EGR no more dirty unburnt gases to contaminate and turn the oil black..

you say oil at the base of the injectors , is it making a chuffing noise at all ?

Overfilled by a litre+ no wonder your poor thing is smoking

Blank off the EGR Valve more trouble than they are worth.... no pcv valve

:Remove intercooler and pipes and clean clean clean . eventually the smoke should go

Cheap oil is a definite no no, Quality oil unless you want to kill your turbo etc.

once you have blanked off the EGR no more dirty unburnt gases to contaminate and turn the oil black..

you say oil at the base of the injectors , is it making a chuffing noise at all ?

Hi Andy,

Thank you for the reply, yes she's puffing blue smoke like a gooden bless her. No there's no sound from the base of the injectors, it just seems to seep at higher revs, it wasn't doing that. I'm just wondering if it's something that's oil blocked?

I'm glad you've confirmed the intercooler to be cleaned, I was thinking about doing that, so I'll dig out the cleaning gear lol.

I have reduced the smoke but at times it's quite bad, I suppose that's understandable.

So do you find blanking the egr valve off better?

I've already got some new oil, got to give her some of the good stuff, I hate cheap crap, I agree with you it's never good for long life of an engine or turbo!

Thanks again,

Sean.

For me and my 1.6Tdci I had a terrible flat spot around the 1000-2000 rpm and you had to rev the old gal to pull away, since adding the £4.25 stainless blanking plate this has gone and also a tad more responsiveness from the throttle and as Lenny on here has done a great write up on fitting the blanking plate and also fitting a Green (performance) air filter this has two advantages 1:better air flow and 2: you simply clean it every year instead of buying a new filter.

Look up LENNY for all his fantastic HOW TO'S

There has been many posts about blanking the Egr valve and all very positive responses indeed and don't forget with it blanked off after a couple of oil changes the oil wont get dirty as like I have said unburt nastys are not going back into circulation oh and you do get a bit better MPG too , happy days :D :D

Good oil for sure and naturally filter to and a regular fuel filter change as well. :driving:

Hi Andy,

Thanks for the info, I like the idea of the EGR blanking plate and will have a look at Lenny's tips for sure. Just out of interest, if I blank off the EGR, will the ECU throw a hissy fit?

When I clean the intercooler, I will also take off the oil return pipe from the turbo to the sump, check it's not blocked or air blocked. I am also going to clean the Intake air shutoff throttle body and fingers crossed it will help her clean out the gunk lol.

Usually its just the 2.0 ltr diesels that sometimes gives a fault codes due to blanking the the EGR..

Get cleaning my man .........

I am going to fit an EGR blanking plate for sure. I've spoken to Lenny, great knowledgeable guy and very helpful!

I've now cleaned the intercooler, it was a little sludgy to say the least. I've also cleaned the turbo oil return pipe, for piece of mind I am going to replace it. I have used some Archoil AR6400-D Pro PEA Concentrate Diesel Cleaner (fantastic stuff works and I recommend it), in the fuel tank and I put a few splashes through the turbo inlet to break down the oil and do a clean throughout the intake system (mainly the bits I can't get to). I then took her up to 3500 - 4000rpm for around 15 mins while stationary, the Archoil & clean has done a fantastic job, she puffed out a lot less blue stuff and towards the end of the 15 mins I red-lined her for about 5 seconds. She struggled past 4500rpm then a good load of junk poofed out the exhaust and she hit 5200rpm. I then dropped her rev's down gradually to slowly cool the turbo and it was smelling like burnt diesel not oil ;) - I let her idle for a while, then blipped the throttle and no blue smoke Yayyyyyyy!! Did a cold start this morning, no blue to start, a little showed on blipping the throttle but it's 100% clearing out the oil and smells 1 million % better. She's now getting a lot hotter and the back pressure seems to have gone (touch wood). I've cleaned round the base of the injectors, there's been no more oil, so that was clearly all down to the back pressure. I will do another good session to burn off as much as I can then resume normal usage of her.

I'll keep you posted on progress.

Cheers

To be clear anyone reading this post, I have some knowledge of cars so I am comfortable pushing them when I feel it's ok to do so, if you are not sure PLEASE DON'T RED-LINE or over rev your car, you could damage it!

A good result there Sean :D , Yep Lenny is a top bloke always willing to give a helping hand.

I have to say after being on other car forums this is far the best by far, no stupid sniping or digs at people just good friendly people willing to help, A BIG FAMILY.

A credit to Moderators and staff and ALL MEMBERS :D :D :D :D :driving: :driving:

I agree there Andy, I normally don't bother with a lot of forums for that reason. I read a few posts on here & everyone seems great, so I joined, I'm glad I did to be honest!

Sometimes it's great to thrash out ideas or get reassurance if you're not 100% sure on things, to be fair both yourself and Lenny have been really helpful so thank you for that :)

Update:

I have done another 15 min session (not so sure the village is to pleased lol), the exhaust gasses are not noticeable, just get the odd minor wisp of blue (that will clear in time) and the car is running like a dream. I will now use her out and about. I am just glad they've not done any damage to her :) Next step EGR blanking and uprating the air filter.

I can openly say I'm a happy bunny :)