Help needed again

[Funkycarldog]

Hi all,
Mk7 2.2 fwd 62 plate
I'm trying to solve an issue with a white ish smoke, but there's a lot of it.
Things I've changed to date:
* New turbo that went in 2 weeks before the white smoke appeared
* Replaced 4 recon injectors with seals
* Rocker cover and gasket
* New head gasket
* Timing chain
* Coded the injectors (all correct)
* Started it back up

But the smoke is still there. Even at idile I don't lose any water. Does anybody have any ideas what it could be? It looks like I may have changed things that didn't need doing. But i love my van

[tranmx2]

White/grey smoke - unburnt diesel, water particles in the exhaust.

Coded the injectors (all correct) - 2012 injectors don't need coding.
Replaced 4 recon injectors with seals - Was the face within the head recut? The face that the copper injector washer/seal is on.
Was the DPF cleaned/cleared. Previously did the DPF regeneration occur? Over time ash builds up inside. See ORiley DPF youtube.
Is the vehicle outside? Is the area the vehicle is in damp?
Was the exhuast left outside?
Could be moisture within the exhaust - would need a 30 min or more run to clear it. December - good time to find whitish smoke - high humidity.
Is the air inlet system free from oil/gundge? The gundge might hold water/ moisture.
EGR cooler leak - EGR valve not fully closed.

[metalworker0]

causes of white smoke
1. normal on a cold day
2. EGR cooler
3.head gasket
4 cylinder head cracked

you say its not using water.

to start the diagnoses.

disconnect EGR cooler hoses and join them together , if smoke stops you've found the culprit

doesn't stop .. next stage is

do a test with a coolant system pressure tester ,.. pump it up to 15 psi .. if white smoke increases its loosing coolant. if it cant hold pressure .. its loosing it somewhere, if pressure increases when cold .. it's the head gasket

i could go on with more tests , but that's enough for now .

all the best.mark

[Funkycarldog]

Thanks for the reply.

I had the head re-skimmed with all new gaskets, including a new rocker cover. The smoke is not cold smoke. It fills the street in minutes and has a bit of a fuel smell to it.

I checked the DPF levels: 20% load and soot. I will try the cooler to see if that's any better. Is there a way to bypass the EGR to see if that's what's causing it? Everybody says it's the head gasket, but I don't lose any coolant.

[metalworker0]

the egr cooler .. i described above, take off the inlet and outlet coolant pipes .. join them together .. don't know if 15mm,, copper plumbing pipe can be used, but worth a try.

all the best.mark

[Funkycarldog]

Hi Mark,

I managed to bypass the EGR cooler, and the smoke was still the same. As I said before, I'm not losing any coolant. When I start it and let it idle for about 5 minutes, there is no smoke, but if I touch the throttle, the smoke will pour out and fill the street. If I let it idle again, it's still there, but not as bad, though still a lot. I have no fault codes come

[metalworker0]

One cause can be valve seals or worn valve stem guides, which you should have addressed when the head was off if you did a full job..... it's typical when these are worn for it to act like you've described, after a period of ticking over, then back on the throttle. but that is a gradual thing that gets worse over time .. no sudden onset. valve stem seals after age and high mileage ... guides after high mileage .. and neglect. high mileage being anything over 180,000 miles

Others
Turbo_ you say the turbo failed .. it can take sometime to burn all the deposits out of an exhaust system once that has happened .. maybe 50 fast motorway miles

Breather system . there have been instances with the rocker covers with orange rubber breather valves ... they fall out. so messing up the way it breathes , and the way it runs. from build date Euro-5 started Sept 26th 2011 .. these are the ones that this happens to.. may make the air leaks or pull oil into combustion chambers.

Happened here before .. someone put a catch can on and completely plumbed it the wrong way.

You have left off a breather hose and not put it back.

The top of the rocker cover chamber is blocked with carbon

injector seal problems, causing pressurisation of crank case.

Worn out engine

and read this lot

https://www.uti.edu/blog/diesel/what-ca ... el-engines

all the best.mark

[Funkycarldog]

Thank you for the reply.
Very interesting read.
I had the valves, stems, and seals done when they skimmed the head.
The breather pipe part came in the new rocker cover I bought.
Would a cracked piston ring give me the same issue? That's the only thing I never looked at because there was no piston slap or markings in the bore.
Could it be the copper seals on the injectors? They were from eBay and not seating properly.

[metalworker0]

Yes it could be the copper seals .. sometimes the seats may need re-cutting to make them seal. ..the seals failure to seal is usually indicated by chuffing out of the oil filler hole when cap taken off, you could do a compression test to find out if a ring has gone, a ring may also cause chuffing and oil consumption problems.

all the best.mark