2011 2.4L 115 Black smoke issue

[simonwood]

Hi all,

my van has recently started putting out black smoke under (heavy) acceleration. More noticeable when cold but still visible when fully up to temps.

I had an error code around the time this started P1102, MAF sensor was dirty, cleaned that and the code never came back. (that said the van does not get used over winter, so this is the first real driving this year)

Looking at live data MAF vs EGR commanded feels sensible (heavy accel, 0% egr, 60-90 MAF reading at higher rpms, at low power driving egr opening a bit, MAF dropping a bit).

Boost pressure looks low. Highest I can get is 5.7psi (2nd gear up hill 4 to 4.5k), typical driving is 0-1psi, normal acceleration 2.5, harder around 3.5psi. I expected to see some more, but no idea what it ought to be.

Any suggestions of where to look?

TIA

Simon

[simonwood]

Looks like I've answered my own question...

20240415_185536.jpg

Now to see how to fix that.

[simonwood]

Sorted.

New plate made and welded over the top of the old (in situ). Should keep it going for a few more years.

If anyone is interested, 2.4 115 seems to have just under 16psi boost with a working waste gate.

20240424_174801.jpg