Smoke, terrible fuel consumption, down on power - mk7 2.4

[HughF]

The above symptoms (smoke is black) have appeared recently, 22k miles after the engine rebuild - I've checked the following:

Air filter is clean
EGR not stuck open
Replaced turbo cartridge as it was worn and putting a bit of oil into the inlet
Done a turbo test on IDS - pass
Fuel pressure at idle is stable - recent SCV fitted

Where should I look next? It doesn't breath out the oil filler so I think compression is still good, even though it turns over mighty quickly on the starter. It's either excess fuel/poor atomisation (injectors are shot, fuel pressure is low) or lack of air...

[ake]

Check all boost pipes and intercollegiate for boost leaks

[amlav]

Also worth to check the MAF air flow sensor and the Inlet boost sensor (the one on the turbo hose) for gunk build up .

[HughF]

Checked all the hoses/intercooler, no splits. Ran a turbo test in ids which should test the maf/map sensor and turbo - that passed fine.

I hopped out yesterday morning, went to restart and it was running on 2, pulled injector plugs on 2 and 3 and they weren't firing.

Went back to recover it last night, ran a rail pressure test in ids, rail pressure is fine, as is crank/cam sync... now it won't fire at all.

Will put the scope on the injector plugs and check we have drive to those, then pull the injectors/rocker box off and see what's going on. I always threatened to make it into a small cube if it gave me any more trouble, here I am fixing it again

[HughF]

Sync was coming and going, put a pair of sensors on it - no difference...

Pulled front cover, inlet cam retarded 4-5 teeth, chain stretched to the point the tensioner ran out of travel and the chain was slack.

23k miles on a TPUK aftermarket chain kit. I see now they ship it with a 'genuine chain'.

Anyway, parts on order, throw it back together tomorrow night.

[MK7 user]

No offence intended Hugh....I'm shocked that a man of your calibre would use an aftermarket kit.

Plenty of problems on this board from people having done the same.

[HughF]

I figured it would probably go the distance, and didn't do my research into which chain to get when I rebuilt it last year. You buy cheap, you buy twice...