Mk7 09 2.2 TDCI black smoke on acceleration

[Tryfan]

Hi
I am sure this has been discussed previously, but have checked and actioned most of suggestions and still have the same issue:
All filters changed
Injectors replaced and pilot learn completed without any issues
MAF sensor replaced
MAP sensor replaced
EGR valve replaced
All inlet, turbo and intercooler hoses checked no cracks or leaks
Turbo checked no play
No lights on dash no codes showing via Forscan
No starting issues or idling getting 30-32MPG
Therefore only issue is the black smoke on low gears and acceleration...anyone think of anything else I could check??
Thanks

[metalworker0]

Think you need to do a compression test ..

all the best.mark

[Tryfan]

Thanks Mark I will ask the garage to check,....I have no performance issues..just the black smoke

[metalworker0]

Clever diagnostics people know how to do the compression test without disturbing anything ..no compression tester needed..just the diagnostic gear reading how many amps starter is using when its cycling and seeing on a graph the peaks and lows of each cylinder as amp draw.

all the best.mark

[Tryfan]

Thanks again Mark, the garage may have already done a test, but I will ask as per your suggestion

[knobby1]

Thanks Mark I will ask the garage to check,....I have no performance issues..just the black smoke

90% of the time, black smoke is caused by a boost leak. Check "ALL" boost pipes/hoses and intercooler for splits.

Lord Knobrot

[Tryfan]

Thanks...the garage said that they have taken all the relevent hoses off and checked for any splits leaks etc..but I guess that they could have missed something

[ned]

How bad is the black smoke?

I’ve noticed more and more diesels are putting out a bit of black smoke, I’m wondering whether a it’s this shitty b10 fuel

[Tryfan]

Hi
Yeah could be, but with new injectors, filters and EGR I would have expected for it to have been OK for a while if it was just a dose of bad fuel

[Tryfan]

90% of the time, black smoke is caused by a boost leak. Check "ALL" boost pipes/hoses and intercooler for splits.

I have checked again of which hoses were checked,... they checked the inlet from the air filter to the turbo including the breather pipe, the hose from manifold to the intercooler and from the intercooler to the turbo. Is there any other hoses or sensors (other than the MAP and MAF sensors that have already been replaced) that could cause the smoking?

[Airthies]

The inlet manifold is plastic, not unheard-of to have a split/crack in them.

How long have you had the van Could it have had a remap that is a pretty basic "MORE FUEL CAPTAIN!!!"
type which will give more smoke.

[Tryfan]

Had the van 2yrs it's o ly done 38k but bit of smoke since I had it..not been mapped

[knobby1]

Had the van 2yrs it's o ly done 38k but bit of smoke since I had it..not been mapped

"not been mapped"....that you know of.

Split inlet manifold is a good call by Airthies too....some of them split along the moulding seams...they're only plastic....or the manifold to head seals may not be happy.

Lord Knobrot

[Tryfan]

Still at its original 130bhp according to the garage..I will ask them to check inlet and the manifold head seals, I am sure that its one area that they haven't looked at yet..would that show up anything in the diagnostics?

[knobby1]

Still at its original 130bhp according to the garage..I will ask them to check inlet and the manifold head seals, I am sure that its one area that they haven't looked at yet..would that show up anything in the diagnostics?

Boost leaks and a poorly EGR often show up as MAF/MAP fault codes. The diagnostics system isn't as smart as we think it is...sometimes it doesn't have fault codes to describe certain issues nor does it have the memory to store a lot of fault phrases etc...

Lord Knobrot