Ford Transit Mk 7 2010 RWD some smoke issues when around 170

[kendare]

Been struggling finding out the cause of this problem for a while now. The engine starts straight away ticks over nice at normal idle speed and drives lively and smooth until full warmed up temp. Then sometimes usually gear changing it hesitates,puffs black smoke out then drives good again after 2000rpm! Going up hills it sometimes hesitates with the similar problem like limping?, but then behaves good,plenty of power there as it had a New Ford Short block fitted 25k miles ago. There are no fault codes on my OBD2 .It has been recently diagnostic checked, and also I have had a new EGR fitted by a garage, A new Turbo fitted,and feed pipes etc by qualified mechanics who use decent spares supplies. The MAF has been checked and cleaned as a precaution and readings seem fairly normal ,Air Filter changed,Oil Filter and Oil Changed, Flushed.,Fuel filter changed, Carbon Cleaned by a company. The injectors were new when the block was fitted,(28km) ,I have put some Wynns injector cleaner fluid in also. After running the van for a few miles I left the engine ticking over and emulated a MOT smoke test spec that is done at approx 2500rpm for 20 seconds duration and the exhaust looks clean with no smoke of any colour in abundance. Don't know what to go for next! Any ideas as it is so annoying! Thanks Ken

[knobby1]

Been struggling finding out the cause of this problem for a while now. The engine starts straight away ticks over nice at normal idle speed and drives lively and smooth until full warmed up temp. Then sometimes usually gear changing it hesitates,puffs black smoke out then drives good again after 2000rpm! Going up hills it sometimes hesitates with the similar problem like limping?, but then behaves good,plenty of power there as it had a New Ford Short block fitted 25k miles ago. There are no fault codes on my OBD2 .It has been recently diagnostic checked, and also I have had a new EGR fitted by a garage, A new Turbo fitted,and feed pipes etc by qualified mechanics who use decent spares supplies. The MAF has been checked and cleaned as a precaution and readings seem fairly normal ,Air Filter changed,Oil Filter and Oil Changed, Flushed.,Fuel filter changed, Carbon Cleaned by a company. The injectors were new when the block was fitted,(28km) ,I have put some Wynns injector cleaner fluid in also. After running the van for a few miles I left the engine ticking over and emulated a MOT smoke test spec that is done at approx 2500rpm for 20 seconds duration and the exhaust looks clean with no smoke of any colour in abundance. Don't know what to go for next! Any ideas as it is so annoying! Thanks Ken

Cheap OBD-II readers and generic garage diagnostics don't always talk to Transits well...you need to get Forscan onto it.

Which engine, 100, 115 or 140..?? When the new turbo was fitted, was a new actuator fitted as well..??

Lord Knobrot

[metalworker0]

just been reading all your old posts on this , we've been through everything.

so now clutching at straws with answers

couple more .. breather device on the rocker cover , now if that was malfunctioning it could spill the turbo boost and introduce oil into the system

this is the 2.4 in an LDV leyland-daf-vehicle

hope it has the same breather system ... as i don't have any other info, busted , cut diaphragm etc .. may be it

Fig.1 Engine breathing system
1. Air bleed hole 4. To turbo air intake
2. Diaphragm 5. From crankcase/camshaft chambers
3. Spring
DESCRIPTION
The Duratorq engine utilises a closed breathing system.
A valve is built in to the right hand rear of the camshaft cover. It is linked by an external
pipe to the intake air duct near the turbocharger. The valve comprises a diagphragm and
a spring. In its rest position the diaphragm is held up in the open position by the coil
spring underneath it. A small hole in the valve cover allows air to enter if the conditions
require the valve to close.
The system works as follows:
The depression created at the lower end of the breather pipe by air being drawn into the
engine causes air to be drawn through the pipe and fumes to be drawn out of the engine
through the valve. Any pressure build up in the crankcase can pass freely upwards
through oil drain passages in the cylinder head and camshaft carrier to the rocker area
under the camshaft cover, and will be dissipated though the breather pipe in the same
way.
Under conditions of high depression too much suction could be sufficient to pull oil
through the system, into the combustion chambers, and create smoke. To ensure this
cannot happen the high suction will cause the valve to be pulled down against spring
pressure and shut off the air flow.
NOTE:
1. If the breather hole in the valve cover becomes blocked the diaphragm will be
unable to be pulled down sufficient to close the valve, and black smoke will result.
Do not stick labels on the valve cover. Use the end of a paper clip or similar to
unblock the hole but do not push in too far – the diaphragm may be pierced.
2. If the diaphragm becomes split, this will allow air to be drawn in through the valve

[kendare]

Hi,Thanks for your response, 115 engine,yes a new actuator was included in the Turbo and set up by the mechanic, Ken

[kendare]

Thanks for the detailed info and diagram you have included. I can mention this to the mechanic who is coming to examine my van and hopefully he may be able to get some solution as to the problem,Regards Ken

[andz327]

Connect to forscan and get live data readings when the fault is happening, when you changed egr was ut due to this problem? Or did it happen sometime after egr fitment , what was last item fitted prior to getting this problem?

Sent from my SM-G990B using Tapatalk

[kendare]

Hi,Thanks for your response. The problem was more consistent before I had the EGR fitted. It had improved somewhat since the EGR with better running performance but still bucked when revving occasionally. The latest component I had fitted was the new Turbo (The old one had play in it and oil build up) with associated pipes,actuator and again the van performed better but with still this occasional problem of smoke puffs usually betweem 1700rpm and 2000rpm Regards Ken