blackwolf wrote:

It is common, almost normal, for a cold 2.4 to produce blueish smoke on startup and this is generally not something to worry about. It shouldn't do it when warm or hot though.

I don't think a stuck-open EGR would cause blue smoke and it would produce DTCs.

A 2009 engine could conceivably suffer from the PCJ hysteresis problem which causes destructive wear to bores and pistons. Do you have any evidence to make you believe it was running clean before its accident? What happens if you remove the oil filler cap with the engine running?

I would suggest a compression test would be a sensible next step, and taking a look at the bores with an endoscope through the injector holes. Alternatively take the head off for an inspection.

blackwolf wrote:

Yes, missed the bit about the compression test!

Is the inside of the inlet manifold oily? Is the intercooler full of oil from the old engine?

andy63 wrote:

Hmmm well I'll be at odds with bw..
If your egr valve was allowing loss of air it could well produce smoke...but Id still be inclined to get a smoke test done just to make sure the inlet side is tight..
Yes I would expect codes if its severe enough..but at least the egr is common to both engines producing the same symptoms so seems like a good place to start given its one of the few items not mentioned in the previous comments..

I thought the op had already got compression test results that were good??

MK wrote:

I have been around at several injector test benches performing tests and I have the impression they deliver pretty much useless results, except if an injector is trully bad or leaks. I can only speak for the 2.4 Denso injectors.

jbcollier wrote:

Has it been remapped? If so, by whom. A lot of fly-by-night mappers were popular back in the day. Mine was mapped by Bell who are very well regarded and it still has glitches. Below -10C, at very light throttle and going down hill, it puts out a lot of blue smoke. A wee bit warmer outside and it disappears. This is when the engine is at temp.

Off topic but engine mapping is way more complicated than it seems. I think a lot of issues are caused by mapping and then not fitting and minding a EGT. Mine has a basic 150 Bell map and I could wrap (needle past the bottom and coming back up again) the EGT gauge very easily on a hill and my gauge reads to 2K°F!

Back on topic, I think your injection system is somehow thinking it needs more fuel. Bad MAF, MAP, CHT sensors. Wiring issues therein. Air leaks in the post turbo intake system (thinks there's more air than there actually is), etc.

lbdmp wrote:

... Could the central silencer also be full of oil and causing this problem?