Another Black Smoke Thread!

[Pimpdaddydog123]

My FL1 TD4 has been smoking from the exhaust and performing badly (0-60 is taking 28 seconds).

If I disconnect the MAF performance improves (but still not as good as it should be) but the exhaust literally plumes black smoke throughout the rev range.

I have looked at all the air hoses in the engine bay and they seem fine, is it possible that the hose from the turbo to the inter cooler has gone or the inter cooler itself?

Definitely seems to be over fueling to me but I can't work out why?

How easy is it to access the turbo to inter cooler hose?
Thanks guys!

 

[teddywood1]

definitely sounds like a hose has gone there are no moving parts in the intercooler it is just like a radiator so check and then check again all the hoses especially the elbow one that's the one on the right the small one

 

[Pimpdaddydog123]

Thanks Teddy but how do you get to them?
I have checked the ones on the engine bay but there must be one from the turbo to the intercooler. Is it behind the front bumper?

 

[Arctic2]

I would personally remove the inlet manifold along with the EGR and its associated hoses, once the manifold is off the car, remove the EGR clean it out with some rags etc you can use swarfega and an old tooth brush, then wipe out once again then you spray carb cleaner into the EGR making sure it does not enter the hole that the EGR solenoid hose fits to.

Remove the MAP sensor from the manifold 10mm bolt, clean the MAP sensor by wiping it clean once again spray across the little hole outlet not into it wipe clean.

You now need to clean out the manifold this can be done by spraying oven cleaner into the manifold let it soak for about 2 hours or more, then jet wash it out completely, repeat if needed.

With the manifold removed check the intercooler hose at the front of the car, you can remove it by looking for the jubilee clip at the bottom of the hose. renew if needed, change the air filter, change the PCV filter.

 

[Nodge68]

I have checked the ones on the engine bay but there must be one from the turbo to the intercooler. Is it behind the front bumper?

All the boost pipes are visible inside the engine bay.
The 2 for the intercooler are arrowed in this picture, red for hot boosted air going to the intercooler, blue for cooled air from the intercooler.

 

[Pimpdaddydog123]

Thanks for the help guys, greatly appreciated! I replace the ccv filter last week when I serviced the car and I ah e now thoroughly clean the inlet manifold and egr.
I have thoroughly checked every inch of hose working the engine bay and there are no leaks. I’m beginning to suspect the turbo and will investigate further tomorrow

 

[Pimpdaddydog123]

Success!

I resigned myself to pulling the turbo today and when I removed the plug from the turbo actuator pressure converter I found a broken wire.

Soldered the wire and re-connected and the performance is now back to normal and no black smoke.

This plug normally resides at the bottom of the engine and can be reached from inside the right hand wheel arch.

 

[Nodge68]

I removed the plug from the turbo actuator pressure converter I found a broken wire.

That would do it, but that would have flagged up a code on a diagnostic. So I'm assuming a diagnostic wasn't run on it to help identify the fault.

At least it's sorted and was a free fix.