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ior

Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10

2007 Defender 90 Puma 2.4 XS CSW Caledonian Blue

Power surging & black smoke

Hi all - looking for some expert opinions please....

I have a 2007 2.4 TDCi 80K miles.
It's been running fine apart from a VERY noisy EGR valve. So I thought i'd try EGR cleaner (as an aerosol spray into air intake at 1 second intervals until used up). After this I noticed it was power surging when cruising on the motorway. On each surge there's plenty of black smoke from exhaust. So I replaced the EGR valve at the weekend (brand new OEM part).

This has made NO difference to power surge & smoke. Just have a much quieter "chugga chugga" clean cycle from valve.
My plan is to give it a full service (oil and all filters) and replace the MAP and MAF sensor (I did clean both, but no affect).
After reading other threads about power surge, several have suggested replacing the Fuel Vapour Valve (VCV).

Any thoughts please ?!

Cheers
Ian

30th Jan 2020 9:56am

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8020

2011 Defender 110 Puma 2.4 USW Stornoway Grey

i dont believe the VCV will give black smoke, it will give hesitant idle until warm.

it is black smoke as excess fuel or black particulates clearing out of the exhaust from what ever was sprayed in it. How many miles since application. Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

30th Jan 2020 1:29pm

ior

Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10

About 100 miles since the EGR cleaner.

But surely this isn't causing the power surging ?

30th Jan 2020 1:47pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20325

EGR sticking closer I would say.
I had no end off issues with mine, and it wouldn’t run nicely at all. Even started playing up 6 months after fitting a new EGR ⭐️⭐️God Bless the USA 🇬🇧🇺🇸 ⭐️⭐️

30th Jan 2020 2:19pm

ior

Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10

The brand new OEM EGR valve is literally 3 days old so it can't be that.

30th Jan 2020 2:32pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20325

Have you checked it for DTC’s though? There could well be a carbon deposit back up that has been deposited now in the new EGR. ⭐️⭐️God Bless the USA 🇬🇧🇺🇸 ⭐️⭐️

30th Jan 2020 5:08pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17362

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

I'd be checking for split intercooler hoses or a split intercooler.

Incidentally there is no power on earth the would make me squirt an aerosol EGR cleaner into my engine. Even if it worked (which I doubt) any dislodged crud is going to go straight into the engine.

30th Jan 2020 6:17pm

ior

Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10

Thanks for tip Blackwolf. Will investigate the intercooler. And yep you're right - stupid lazy decision to use EGR aerosol.
I disconnected the MAF this morning and seemed much better - no surging and significantly reduced smoke. I've ordered a new one so hopefully that was the cause.
Cheers

31st Jan 2020 8:59am

ior

Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10

Solved!

A big thanks to Blackwolf for sussing out the issue.
It was a badly split intercooler pipe causing all the grief.
Now fixed and pulling like a train again

8th Feb 2020 6:30pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17362

Excellent news, well done.

8th Feb 2020 8:42pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20325

Blackwolf knows his stuff. 👍🏻👍🏻 ⭐️⭐️God Bless the USA 🇬🇧🇺🇸 ⭐️⭐️

8th Feb 2020 9:06pm

expatRob

Member Since: 24 Feb 2015
Location: Frankfurt
Posts: 58

2007 Defender 110 Puma 2.4 SW Tonga Green

I am getting black smoke out of the exhaust when I hit 4th gear and up. I have a leak somewhere near the radiator top hose area. Could this be a similar issue for me?

1st Mar 2020 8:36pm

ior

Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10

Hi. Yes I suspect it is.
My intercooler hose (near side) had badly split at the "radiator" (intercooler) end.
This hose is quite easy to replace.

2nd Mar 2020 9:30am

Bish

Member Since: 11 Nov 2008
Location: Hungerford
Posts: 427

i have a similar issue.

Very low mileage 2.4 (16,000 miles) that surges under acceleration with black smoke. I had a fault code P1103.

Cleaned both MAF and MAP but still there and much more noticeable when hot.

Split hose, EGR or sticky vanes on a turbo?

5th Mar 2020 5:22pm

ior

Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10

Check the intercooler hoses carefully on both sides - as well as jubilee clips.
Also check the intercooler rad for any split. (might see signs of oil leakage under the rad)

6th Mar 2020 7:47pm

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