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        General >> Problems >> TD - Lots of Black Smoke 
        
(Message started by: Mark_H on Dec 9^th, 2006, 1:51pm)

Title: TD - Lots of Black Smoke
Post by Mark_H on Dec 9^th, 2006, 1:51pm

Last week I was on a drive to Bristol and started to notice loss of power and black smoke on hills. This got worse over the journey. I parked up in Bristol for a couple of hours. When I started the car again everthing was normal for most of the journey back to Bournemouth. On a big hill near home it started to happen again, loss of Power followed this time by lots of Black smoke. It got very bad. I stopped, turned engine off and then started it again, I drove perfectly lots of power no smoke.
Until yesterday. I drove the car for its MOT. No problems at all, no smoke. The car passed with flying colours, untill the smoke test. Clouds of Black smoke everywhere.
I've tried lots of Diesel Boost, the injectors were replaced last year, under 12,000 miles ago and the valves were recut at the same time.
Any suggestions what I should try. Money is tight at the moment so taking it to a diesel specialist is a last resort.

Title: Re: TD - Lots of Black Smoke
Post by taliban on Dec 9^th, 2006, 11:52pm

i've had similar probs with mine.
firstly change your filters; air, fuel. if the air filter is dirty not enough air will get through so the engine will be running rich.
i tried a product on ebay called tech 2000 diesel injector cleaner which worked really well for a limited period i.e. during mot time. with postage it only cost around 6 quid, it does say on the bottle to use a seperate pump and run it through with the engine off, but i just added it to the tank.
there is a vacuum pipe that runs from the top of the diesel pump (banjo connection) to the underside of the inlet manifold (jubilee clip). remove this and clean it through with compressed air or carb cleaner making sure all the small banjo holes are clear. its only a ten minute job and makes a lot of difference.
in the diy/service section of the site there is details on this problem and suggests changing the MAP sensor, a simple job but a new sensor is around 100 quid from ford.
you can also plug up the vacuum pipe to the EGR, this can help a lot.
i've just started running mine on sunflower oil (slightly thinner than veg oil so better in cold weather), apart from no change in performance the only things i've noticed is the tickover is slightly higher, but interestingly there is a lot less smoke...

Title: Re: TD - Lots of Black Smoke
Post by mazzy_j on Dec 11^th, 2006, 5:13pm

Hi Mark, welcome to the site :)

I would happily place my bets on the EGR playing up. Mine did exactly what you've described a year ago, only it was whilst i was rally driving and i thought i had blown the turbo :-X Turned out a couple of the exhaust gaskets were blowing (possible one of the inlet as well) which played havok with the egr and caused it to stick open, dumping exhaust gasses straight back into the inlet manifold hence billowing black smoke everywhere and no power {}

Have a nose around there first of all, then as injector says unplug the little vacume hose to the egr valve and also give the inlet manifold vacume hose a good clean through, gives it a nice kick up the backside ;D

Matt

p.s. did you notice it getting slightly louder, kinda transit van like at all when it was playing up?

Title: Re: TD - Lots of Black Smoke
Post by Mark_H on Dec 21^st, 2006, 4:20pm

Thanks for the advice, I'm going to give the EGR pipe a clean this weekend. How do I disconnect and reconnect the banjo clip. are there any diagrams of these pipes?
Thanks
Mark

Title: Re: TD - Lots of Black Smoke
Post by sector-9 on Dec 23^rd, 2006, 2:22pm

The banjo union has a hollow bolt and a copper washer either side of the 'banjo' itself - you'll find it on one side of the diaphragm housing atop the injection pump. Be careful not to over-tighten it or it could snap. The other end of the pipe is jubilee clipped onto the inlet manifold.

Darren

Title: Re: TD - Lots of Black Smoke
Post by taliban on Dec 23^rd, 2006, 9:56pm

spray the banjo with wd40 first and make sure you use the correct size socket on it....try not to drop the copper washers....just in case you havent any new ones......without them there WILL be a vacuum leak.....