MK7 Black smoke MOT fail

[Armin]

I'm not a mechanic and need your knowledge...
The van has a constant black smoke. even at idle. you can easily smell the unburnt diesel

I have a 2006 Ford Transit FWD with a 2.2L Duratorq TDCI. 3 mechanics and ford stealership looked up the car and couldn't fix it. I cant afford throwing it in junkyard. I need your help...

The smock problem started when I was driving on an Autobahn in Germany. Van fully loaded and was going ~150 k/h, Suddenly went to limp mode and black smoke. Pulled over and shut the engine off, read errors and had Turbo overboost condition P0234 as well as Turbocharger boost control position sensor P2563,EGR vaccum regulator solenoid circuit P1409, U0121, and P1103

Went to Bosch workshop and the guy just felt the actuator arm and said it has excessive slack. you need a new Turbo. 1100 EUR. I couldn't afford it, so I spent the night in Germany and took the actuator apart and shimmed it tight with a thin washer and continued my trip, But it happened in France and Switzerland again. But I was driving more careful.

Back to Norway again, I took it to dealership and they charged me 120 EUR just to say I need a new engine! the engine is too old and that's why I have the black smock problem! They didn't even mention anything about the turbo.
Took the van to another workshop and after 2 weeks they changed the EGR and oil and air filter and still the same...
Driving 110 km/h on a highway on a cold day, suddenly the hose between turbo and intercooler exploded, this time i got underboost...

inlet.jpg

Changed the hose the day after and took it to another mechanic and they said injectors are the problem, they're wornout and that's why you have overboost and smoke, get them overhauled and that should do the trick. I did a leakoff test by myself and here is the results.

Screenshot 2021-04-03 223811.jpg

So took the injectors out and sent for refabrication, after 3 weeks they said it's impossible to fix these. I need to buy new ones... Bought 4 brand new ones and washers and bolts and changed them, still black smock...

in.jpg

Took a time and opened up the whole ducts and intercooler and everything in between. Had a lot of carbon deposit

inlet mnfld.jpg

washed them all to no avail

after.jpg

Inspected the houses and seals and nothing is leaking after turbo. MAP sensor seems to work normally under vaccum and MAF changes voltage after i blow on it.
PRV seems to be fine, tested by pulling out the connector and there's no leak (maybe one drop and then stops)
I don't know how to check SCV
Didn't do a compression test, don't have the equipment
a couple of days ago it was -15 deg and van starts just fine. always starts very easily, even without the Eberspächer heater on
Also has new glow plugs. and new battery

3 things that may or may not be related:
Please watch this video. When I uncap the oil inlet, I can feel air pumping out (but it's not pressurised at all)
https://youtu.be/sj5fEqYRqMw

Also, I have bobbles in my fuel pipes, I assume it's not normal, or is it a self bleeding common rail?
https://youtu.be/TKcIWldt_gU

and the last mystery, I'm not sure what this cable and attachment bracket is, but mine is broken. I assume it's just a non conducting piece of plastic and more like a cable holder. Is it?

[Armin]

and the last mystery, I'm not sure what this cable and attachment bracket is, but mine is broken. I assume it's just a non conducting piece of plastic and more like a cable holder. Is it?

Screenshot 2021-04-03 230651.jpg

The symptoms I have:
[*]Very high emission even at Idle (even without turbo kicking it)
[*]Black smoke at higher RPMs (~2700) and shifting gears

I never experienced lack of power, nor rough idle. But I'm also not a mechanic, so i'm not sure...
One last thing is the behaviour of turbo and the way the actuator excites over different RPMs.

25.jpg

If you look at the above screenshot and particularly VGTDC (which is the duty cycle of turbo actuator), It's either 0~10 % or over 200%
It goes over 200% and there's no actual step inbetween. It just jumps even tho I'm giving the accelerator pedal a very slight depress.

55.jpg

Is that a normal behaviour?
I took it apart and there's no slack at the turbine nor the bearing. Also the variable vanes are moving freely.

Thanks a million

[Armin]

Here's a video of the actuator that syncs with the graph I posted before
https://youtube.com/watch?v=P-Eplg61c20

[loot]

and the last mystery, I'm not sure what this cable and attachment bracket is, but mine is broken. I assume it's just a non conducting piece of plastic and more like a cable holder. Is it?

Screenshot 2021-04-03 230651.jpg

The symptoms I have:
[*]Very high emission even at Idle (even without turbo kicking it)
[*]Black smoke at higher RPMs (~2700) and shifting gears

I never experienced lack of power, nor rough idle. But I'm also not a mechanic, so i'm not sure...
One last thing is the behaviour of turbo and the way the actuator excites over different RPMs.

25.jpg

If you look at the above screenshot and particularly VGTDC (which is the duty cycle of turbo actuator), It's either 0~10 % or over 200%
It goes over 200% and there's no actual step inbetween. It just jumps even tho I'm giving the accelerator pedal a very slight depress.

55.jpg

Is that a normal behaviour?
I took it apart and there's no slack at the turbine nor the bearing. Also the variable vanes are moving freely.

Thanks a million

That plastic holds the glow plug bit next to it and it is live so is insulated from the engine.

[loot]

Also unplug the turbo to see if the smoke stops. (before you check or change anything else)

[Armin]

Thanks for the reply. Made no obvious difference...
I got the below codes

Screenshot_20210405-093014_FORScan Lite.jpg

Could it be a jumped timing?
Is there a way to verify the correct timing without needing to open the timing cover?
Is air in the fuel line normal? The video I sent in the first post
Thanks in advance!

[loot]

So with the turbo plugged in so you still get codes?

In Ford ids there's a live data reading for 'SYNC' which verifies that the crank sensor and cam sensor are in harmony (99%) anyway.

Look in data logger for sync and yes.

[Armin]

No, with turbo plugged in there's no error
Unfortunately I don't have an IDS. I can get one if it's absolutely necessary.
Let me see if I can do the same with Forscan

[Faris]

@ Armin,

Did you find root cause, my van is a carbon copy of yours. Was it jumped timing chain or something mechanical in those lines?