Remapped Sportvan Black Smoking - Help me resolve

[HA54SYM]

Hi all,

Read lots of posts on this type of subject and starting to narrow it down to a few things.

Some details,

2007 130 Sport with 32k on the clock.

It has some form of remap and I think it must have been on around 1 year or so, but know little else about it. Has service history but apart from first all at independnt garages. Have thought about taking it to Ford for a full service, and diagnose, but want to try and save a few pennies if I can first.

Problems,

Thick Black smoke on hard accelertion, with lots of black smoke on pull off very evident in day light, but van does pull really well. Sometimes a bit boggy, and slow to start, but this has been better since new battery fitted.

I'm thinking it could be the following,

1. Dodgy re-map causing over fueling, would explain the boggyness, and smoke I guess?
2. EGR Valve issues
3. Split hose in inlet somewhere

I will start with going 3 to 1, as I don't mind having the re-map removed if it causes the black smoke to go, and maybe get a re-map from someone I can trust like vantuner or something, but that would be my last option.

Question is,

anything else to be considered, and any speciifics I should be checking?

Obviously out of warranty but want to do as much as possible before the trip to Fords for full service and fault finding.

Thanks in advance,

Dave

[g-man]

overfuelled,but do the other checks,and visit vantuner

[fedup2]

First things to check would be easy ones,air filter and map sensor.
It might pay to pull the egr and have a look if thats clean and working,30 odd thou might not seem alot of mileage but things crud up pretty quick.

This is a map sensor that has done 50 thou so 30 thou cant be looking much better and they are a quick job to check

[HA54SYM]

Why would the map sensor get that crapped up?

Dave

[fedup2]

The whole intake gets the same way thats EGR's for ya

[angeleye]

check intercooler and pipe work as any splits/ damage will cause excess smoke..
when you say remap do you mean remap or a plug in device

[HA54SYM]

Not sure, how would I know if I have a plug in device?

Dave

[angeleye]

plug in device would proberley be ..some sort of small box plugged in to obd port under steering column /or plugged in to the end of fuel rail

[g-man]

The whole intake gets the same way thats EGR's for ya

map sensor is before the egr,should'nt get that bad.........or is it in a different position on a mk7

[fedup2]

Egr valve as I understand it diverts the exhaust gasses into the inlet manifold and the map sensor is on the MK7 in a box bolted to the inlet manifold which has a pipe from the egr in the rear of it firing directly at the sensor.
My money is on this being an Egr fault and no way would I over write the map till is ruled everything else out.

[HA54SYM]

Thanks for all your help lads, I'm going to do some tinkering this weekend and see what I can see.

Any tips or guides on removing the EGR valve?

Dave

[HA54SYM]

OK bit of an update as had some time to do things.

Took the EGR off, all looked fairly normal, although I could not open / move the valve stem at all. so not sure if its working or not?

Decided to also check the map sensor, and as it was so badly covered in crud, I took the whole inle off and cleaned up as much as possible. Could not believe the amount of build up in it!

Not sure if this is normal, or if it is a sign the EGR is not working.

Anyway assembled back together, and still smoking after an afternoons run.

So what next, do I swap the EGR as a matter of course, it rule it out?

Only other thing I did notice was that on one of the injector inlet to heads, it had a lot of what presume is fuel deposit around it. the others looked dry, dirty but dry. Would this be a sign of faulty injector causing over fueling and smoking?

Thanks

Dave

[fedup2]

OK bit of an update as had some time to do things.

Took the EGR off, all looked fairly normal, although I could not open / move the valve stem at all. so not sure if its working or not?

Decided to also check the map sensor, and as it was so badly covered in crud, I took the whole inle off and cleaned up as much as possible. Could not believe the amount of build up in it!

Not sure if this is normal, or if it is a sign the EGR is not working.

Anyway assembled back together, and still smoking after an afternoons run.

So what next, do I swap the EGR as a matter of course, it rule it out?

Only other thing I did notice was that on one of the injector inlet to heads, it had a lot of what presume is fuel deposit around it. the others looked dry, dirty but dry. Would this be a sign of faulty injector causing over fueling and smoking?

Thanks

Dave

Ive recently done my injectors,i found problems with the injectors blowing past (the nozzle copper washer) where the top seal was wet.
You really need to get the injectors removed and tested as an over fueling injector can cause bigger problems.

What i did was pull an injector and went on the hunt for some and ended up getting 3 off ebay that had been used only once for £250.That way the costs are kept to a minimum if your brave enough to have a go yourself.
The job is very easy and the only thing youll need to do is have the new injector/s recoded when your done although it will run ok till you do.
A word of warning though the injector clamp bolts are made of butter and need torquing down
stage 1 6nm
stage 2 180 deg

I had real problems getting one injector out but other than that the job was a doddle and have found no problems from reusing the fuel lines despite being undone countless times.

The leaking injector could be putting diesel in your oil so i would change that when your done.

[Mike]

Just pulled the MAP sensor out of mine (20k miles) and it's not really that bad. Only ever been run on Shell fuel if that makes any difference and it never sits at idle for long (no 30 minute tea breaks with the engine running).

[angeleye]

did you have a good look at intercooler/and pipe work for splits damage