2009 (59) MK7 Transit 2.4 RWD 115 - White Smoke

[ned]

Quick question, does it only smoke on a cold engine? N

[Click4]

Yep new bolts, washers (Genuine) and clamps

Even tried tightening them down a little more.

It was initially smoking intermittently on startup but a quick rev and it went away.

Now it’s become permanent.

Found 2 things though today.

EGR cooler is leaking internally. And injector 1 is under isn’t fuelling correctly so ecu is ramping the fuel up then seeing its fuelling too much and drawing it back in on cylinder 3 to even out engine idling. Maybe injector is not atomising correctly.

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[Click4]

Don’t know why it’s flipping the photos :S

[knobby1]

So it's not smoke, it's steam...as evidenced by your leaking EGR cooler. By-pass the EGR cooler, take her for a decent run and see if the steam/smoke disappears.

Lord Knobrot

[Click4]

Seems to be, but it smells of diesel because of the iffy injector over fuelling

[knobby1]

Seems to be, but it smells of diesel because of the iffy injector over fuelling

Well the EGR cooler is obviously leaking, so I would sort that first, then worry about the injectors after that.

Lord Knobrot

[Click4]

EGR cooler done,

Had been bodged previously.

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Looks like some kind of epoxy was used on it.

Fitted new one which has sorted that, damn thing is still smoking though, not as bad but still bad lol

Van is costing a fortune, everything I touch to try and diagnose the fault I find something else, had to put a new hose on egr Cooler also because the rubber had gone all funny and found hose had been modified also.

[knobby1]

Will take a while for all the old coolant/water to be burnt/blown out of the exhaust, muffler etc....as mentioned before...it's probably not smoke, it's more likely steam.

If it is indeed smoke, you've got issues other than the EGR cooler. Pop the boost hoses of the intercooler and see if there's a silly amount of oil in there. There will be some oil coating the inside of the hoses etc, this is normal.

Lord Knobrot

[Click4]

Yep it will take a while but still stinks of diesel,

Suspect it’s down to this.


Injector 1 the ecu is dumping extra fuel... maybe it’s not atomising correctly.

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Then it is reining the fuelling back on next cylinder to fire, number 3.

Going to check turbo next as well.

But fuelling isn’t right on it still.

[knobby1]

Yep it will take a while but still stinks of diesel,

Suspect it’s down to this.


Injector 1 the ecu is dumping extra fuel... maybe it’s not atomising correctly.

CBC25687-AEFF-425B-8EAC-E7B2F50FFD78.jpeg

Then it is reining the fuelling back on next cylinder to fire, number 3.

Going to check turbo next as well.

But fuelling isn’t right on it still.

If the injector "Pilot Learns" been done successfully, (as you mentioned), they should be OK. The learn process will fail if the injector pressures & flows are not within fairly tight limits.

Lord Knobrot

[Click4]

True but that was done after I replaced the first 2 injectors.

It didn’t start smoking like this till about 2 weeks later.

[knobby1]

True but that was done after I replaced the first 2 injectors.

It didn’t start smoking like this till about 2 weeks later.

You may have to run the learns again, just to make sure the injectors are up to snuff. Might pay to do a "Leak-off" test too.

Did you say 2 of them were "reconditioned"..?? If so did you get new calibration reference codes with them..??

Lord Knobrot

[Click4]

When I got the van it had 2 original injectors in it and 2 recon

The recon ones had square bits stuck over original codes so they did have new codes.

When it first started smoking white smoke, was only a little bit, but did leakoff test, and 1 original and 1 recon injector wasn’t right, they both practically filled bottles up.


So I replaced both of them with brand new injectors and codes them. Did pump and pilot learn and was all good for around 2 weeks.

Then started smoking bad.


Already done a leakoff test again. The 2 new injectors both leakoff equal amounts, and the 1 original and 1 old recon also both leaking off pretty equal amounts but slightly more than the new ones which is expected as they are older.

But none standing out like before.

Only becomes apparent there is an issue with number 1 or 2 when you look at the correctional values. Ecu thinks cylinder 1 is under fuelling so it’s injecting more fuel. Which presumably is causing too large an increase in engine speed so it draws back cylinder 3 to even it out.

[knobby1]

Only becomes apparent there is an issue with number 1 or 2 when you look at the correctional values. Ecu thinks cylinder 1 is under fuelling so it’s injecting more fuel. Which presumably is causing too large an increase in engine speed so it draws back cylinder 3 to even it out.

This doesn't sound right....the PCM isn't smart enough to make those adjustments/changes, it only injects the required amount/timing depending on the engine load, rpm and throttle position in relation to the individual correction factors entered into the system. I'd run the pump and injector pilot learns again, if they are successful, it "should" be running ok...

Have you have the codes read recently...??

Lord Knobrot