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Lots of dark smoke from exhaust, plenty of power in engine

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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby geoffwa3 » Sun Dec 09, 2018 12:32 am

ned wrote:
geoffwa3 wrote:I'm in close to Liverpool bud


Karl's the man you want


Thanks Ned, will give him a shout
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby geoffwa3 » Sun Dec 09, 2018 1:46 am

Karst, just over 12 months ago the engine on my van started to sound like a bag of nails, quite loud and rattley and a few days later on the motorway it started to lose power. I managed to limp home about 20 miles and knew there was something seriously wrong with the engine.

The next morning after ringing around I found a local engine specialist who sounded really knowledgeable especially about transits, he sent a low loader an took my van back to his place. He showed me smoke coming from one of the cylinders and advised that the piston had probably gone but had to take the engine out to further investigate. It was at this point he advised it was going to be a costly repair but would know more the next day.

He rang the next day to confirm his findings and that in fact the pistons and cylinders were surprisingly all ok but a couple of valves had bent and could repair everything. A week later it was ready, from memory new valves, piston rings, head skimmed, timing chain kit. Agreed cash at £1,700

Van didn't feel right it was dying under acceleration, hunting on tick over, loss of power and missing a beat regularly so I took it back but he assured me all mechanicas were 100% sorted. This made me think that there may be some underlying electrical issues so I took the van to a diagnostics centre I've used in the past (Camco 88 Warrington) wish I hadn't!!
They had to replace the fuel pump pressure regulator, fuel filter, egr valve, ECU software update, fuel pump learn. £850

It was great for a few weeks then it started getting sluggish again and not performing properly and sounding rough so I took it back to the engine place who diagnosed number 1 injector was over fueling and needed to be replaced along with pilot learn and an oil change from rebuilt engine. £300

Again felt ok for a few weeks but this time it started to run rough, make odd noises and clanking on start up but more worryingly sounding really rattley again so back to the engine garage. When they heard it he told me to stop driving it straight away as he was worried the timing chain had slipped and could do further damage so had to leave it with them. Rang me later that day to advise it needed another new timing chain kit and as it was just outside the 12 months warranty period I had to pay for it.
Reluctantly I agreed cash at £150.
This made me wonder if the overfueling injector had caused the engine failure in the first place??

This was just a couple of months ago and now I have lots of black smoke under acceleration, it doesn't start on the button as it used to, loss of power and smoothness and a pinking metallic type of noise from the engine a lot of the time .

I'm worried about doing further damage to the engine but I also need my van for my job so in a catch 22 and really p@#sed off

I've spent over £3k in little over a year and I can't afford to throw any more at it unless it's to someone who knows these vans.

Please any help/advise would be greatly appreciated
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby Karst » Sun Dec 09, 2018 4:00 pm

Ouch Geoff ! It can be a right nightmare and you've been through it there.

I'm in Watford near London, so I've had a journey to find a trustworthy mechanic. I think I've found one now. Sorry I can't advise you in your area, did you find the mentioned Karl?
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby ned » Sun Dec 09, 2018 5:17 pm

RUST IS LIGHTER THEN CARBON FIBRE

57 transit 85t260 2.2 swb, moondust silver.
viewtopic.php?f=27&t=209987

03 transit 125t280 2.0 tdci swb 229,000 miles.
viewtopic.php?f=27&t=168296
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby geoffwa3 » Mon Dec 10, 2018 9:31 am

Thanks fellas, Karl sounds like the man I've messaged him just waiting for reply will probably give his garage a call today.
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby geoffwa3 » Mon Dec 10, 2018 9:32 am

Please keep us updated on yours Karst
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby Karst » Mon Dec 10, 2018 11:01 am

geoffwa3 wrote:Please keep us updated on yours Karst

I sure will.

Just mentioned to the mechanic also about a slow oil leak that I forgot about in the chaos.
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby Karst » Tue Dec 11, 2018 9:41 pm

Just picked up the beast today. Just short of £700 to change copper and rubber seals at injectors and EGR valve and a couple of other bits. It also comes with a 12 month warranty on the work. So far so good. Over the next coupla weeks I'll see the proof of this work.
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby Karst » Thu Dec 13, 2018 9:39 pm

So far so good. Plenty of poke in the engine (It amazes me actually. My Mk6 was pretty sluggish with a 2.0 litre diesel engine, and this is only 2.2L but it drives almost like a petrol engine)

There is smoke, but it seems to be on and off before it is up to temperature. Definitely better though. I still need to get it on a bit of a proper run to see the whole kit and caboodle.
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby andz327 » Fri Dec 14, 2018 12:14 am

Karst wrote:Just picked up the beast today. Just short of £700 to change copper and rubber seals at injectors and EGR valve and a couple of other bits. It also comes with a 12 month warranty on the work. So far so good. Over the next coupla weeks I'll see the proof of this work.
£700 you kidding for seals and egr....... At most with genuine seals bolts and clamps and uprated egr should only cost around£150. 550 sheckles for a couple of hours work....... Think i need to get back on the tools

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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby Karst » Fri Dec 14, 2018 9:05 am

andz327 wrote:
Karst wrote:Just picked up the beast today. Just short of £700 to change copper and rubber seals at injectors and EGR valve and a couple of other bits. It also comes with a 12 month warranty on the work. So far so good. Over the next coupla weeks I'll see the proof of this work.
£700 you kidding for seals and egr....... At most with genuine seals bolts and clamps and uprated egr should only cost around£150. 550 sheckles for a couple of hours work....... Think i need to get back on the tools

ANDZ

Andz I phoned Ford directly about the price of the seals - £43 each. And the copper washers - £20 each

The mechanic told me most of the time was taken up by cleaning out the cavity/surfaces where the washers and seals go

There was also something else that needed replacing, a tubes was leaking (don't know exactly offhand)

Anyway, he seems to be the most genuine one so far that does vans around here that I know.
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby andz327 » Sat Dec 15, 2018 1:01 pm

Karst wrote:
andz327 wrote:
Karst wrote:Just picked up the beast today. Just short of £700 to change copper and rubber seals at injectors and EGR valve and a couple of other bits. It also comes with a 12 month warranty on the work. So far so good. Over the next coupla weeks I'll see the proof of this work.
£700 you kidding for seals and egr....... At most with genuine seals bolts and clamps and uprated egr should only cost around£150. 550 sheckles for a couple of hours work....... Think i need to get back on the tools

ANDZ

Andz I phoned Ford directly about the price of the seals - £43 each. And the copper washers - £20 each

The mechanic told me most of the time was taken up by cleaning out the cavity/surfaces where the washers and seals go

There was also something else that needed replacing, a tubes was leaking (don't know exactly offhand)

Anyway, he seems to be the most genuine one so far that does vans around here that I know.
I only use Ford leak off seals these are a must (GREEN O-RINGS) and i sometimes use Ford (slightly thicker)copper washers which they sell to me for £20+vat but the £5 set off ebay work OK and black rubber injector/cam cover seals you get away with buying ebay , new bolts are a must but I've reused these in the past and its been fine , But 2 new bolts and 2 new clamps are less than 30 quid including vat and best to get really , the tool kit to re-cut injector seats to buy is around 18-25 quid and its easy to do , plenty of how to "DiY" help on here and on youtube mate

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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby Karst » Sat Dec 15, 2018 11:45 pm

The thing is Andz, I will put my hand to most things, but I drew the line on this. I hadn't gathered enough info to have the confidence to do it, and I believed I would drop crap into the cylinders while I did it and completely faff it up. Maybe on another day after all this I'd do it.

I'm still getting smoke, mainly when it's cold, so I did a search again for it here. I turned up a very interesting one talking about the problems caused by EGR valves, how they are a bad idea and encourage smoke. So maybe I can rest easy?

One thing - if a clogged EGR valve causes smoke, can't we just clean it out??
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby Karst » Sun Dec 16, 2018 4:39 pm

face-palm_1f926.png


I've just done a daylight road test...

THERE IS STILL BLACK SMOKE ! ! !

When it idles or revs without load - no smoke.

When it is under load of any sort lots of black smoke, in proportion to the load. It's HORRIBLE ! ! !

Are there any simple answers to this??? Please?

Or even complicated answers?
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Re: Lots of dark smoke from exhaust, plenty of power in engi

Postby Karst » Mon Dec 17, 2018 6:55 pm

OK, OK,PANIC OVER ! ! !

I asked the mechanic, and he said it is blowing out congealed soot, it will take 500 - 1,000 miles to get rid of it all.

Aaghh
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