Freelander 1 Black smoke, erratic running & engine management light!

Hi
Yesterday had black smoke out the exhaust of my 54 plate freelander TD4 (130k miles), along with erratic running and the engine management light coming on one week after passing its MOT!
Thanks to this site I think I have it sussed.
The long LHS intercooler hose has split at the intercooler. Also noticed the same hose had been rubbing against two other parts and have alomst worn right through. The clue for the hose being split was the sound of air being drawn in quite loudly.
I am hoping the EM light is due to the a sensor doing its job.
The question I have is roughly how long will it take to replace the three intercooler hoses? Is there any other job worth doing at the same time? Thinking EGR blanking and turbo hoses?
Any help appreciate!
eekie

If I were you I would change the PCV filter, air filter, and clean the EGR out along with the manifold, if cleaning the manifold please remember to remove the map sensor first, ths can also be cleaned with some carb cleaner, check small hose coming from the egr to the vacuum solenoid as these can chafe and also get holed, a few pics below.

Also noticed the same hose had been rubbing against two other parts and have alomst worn right through.

Click to expand...

top hose often rubs against the plastic air-intake mounting screw ( LH as your facing the engine ) ..
easy to cut up a bit of hose ( or similar ) and using cable tie's .. add it over the new hose at that spot ..

replacing those intercooler hoses don't take long .. neither does installing an EGR-delete ..
note: when fitting the hose and clamp over the intercooler lower exit-tube ..
be sure to fit the clamp behind the lip on the tube .. if not the pressure can blow the hose off the tube ..
er .. and that particular clamp position can be an s.o.b. to get a spanner or socket onto ..
easier if you've got a long extension to work with ..
i used a small open ended spanner at first .. was the most time consuming part of int.-hose and egr-delete installment
( plus i neglected the 'lip' on that lower intercooler tube ..
( and the hose blew off like a petrol lump 'backfire' when i gave it some go-pedal up a steep hill ..

we all learn things after the event,its a land rover thing,
we are either dedicated or raving mad..

Arctic2 said:

If I were you I would change the PCV filter, air filter, and clean the EGR out along with the manifold, if cleaning the manifold please remember to remove the map sensor first, ths can also be cleaned with some carb cleaner, check small hose coming from the egr to the vacuum solenoid as these can chafe and also get holed, a few pics below.

Click to expand...

Arctic2 Thanks for that. Had a good look over the hose and decided that I could replace temporarily until the new ones arrive. The lower jubclip was fiddly to remove. I cut the LHS hose at the split and reattached. Restarted and the amount of smoke was worse than before! Just needed a good foot to the floor blast to clean it out - TFFT! Going to change the PCV filter & the inline filter nearby (turbo vent?) Air & oil filters done recently. Will check the EGR and will clean it out. If the EGR is full of crud then may consider also ordering a bypass egr.
Thanks

hd3 said:

top hose often rubs against the plastic air-intake mounting screw ( LH as your facing the engine ) ..
easy to cut up a bit of hose ( or similar ) and using cable tie's .. add it over the new hose at that spot ..

replacing those intercooler hoses don't take long .. neither does installing an EGR-delete ..
note: when fitting the hose and clamp over the intercooler lower exit-tube ..
be sure to fit the clamp behind the lip on the tube .. if not the pressure can blow the hose off the tube ..
er .. and that particular clamp position can be an s.o.b. to get a spanner or socket onto ..
easier if you've got a long extension to work with ..
i used a small open ended spanner at first .. was the most time consuming part of int.-hose and egr-delete installment
( plus i neglected the 'lip' on that lower intercooler tube ..
( and the hose blew off like a petrol lump 'backfire' when i gave it some go-pedal up a steep hill ..

Click to expand...

Hi HD3
You were spot on about the jub clip a wee 6mm spanner did the job. Will make sure about locating the clamp correctly.
Did you notice any difference with the EGR mod?

Did you notice any difference with the EGR mod?

Click to expand...

yeah .. better mpg for starters ..

i got rid of the egr valve some while before adding a tuning box ( synergy2a/ronbox )
when i first got the hippo .. it took me about two weeks to get used in making a standing start uphill
if i didn't give it some revs and slip the clutch .. in 1st gear ..
the vehicle would shake-shudder something effing awful ..

in fact i let a mate drive it .. and he's a driving instructor with plenty of time on diesels ..
but never driven a land-rover of any kind ..
we came to a stop light on a steep-ish incline .. when he started off the hippo morphed into a kangaroo
i thought he'd selected 3rd gear by mistake .. but he hadn't .. he was in 1st ..

anyhow .. getting rid of the egr valve got changed of all that ..
no more juddering 'n shaking .. or having to slip the clutch in similar situations ( well mostly )
adding the tuning box made it even easier to make smooth getaways uphill ..
and absolutely no need to slip the clutch at all ..
( the tuning box plus pierburg maf gives far better response at the lower rpm .. and upward )

Had this issue some months ago, When read with a diagnostic it resulted in 'Rail pressure fault' we replaced pressure sensors and all. still the same. checked further and had a worn tip on one of the injectors. changed and presto!

Sounds like a normal day.