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ior



Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10
England 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
Post #812654 30th Jan 2020 9:56am
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jst



Member Since: 14 Jan 2008
Location: Taunton
Posts: 8024
 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
Post #812692 30th Jan 2020 1:29pm
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ior



Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10
England 2007 Defender 90 Puma 2.4 XS CSW Caledonian Blue
About 100 miles since the EGR cleaner.

But surely this isn't causing the power surging ?
Post #812700 30th Jan 2020 1:47pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20348
United Kingdom 
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 $W33T $0U7H3RN $UG4R
🇬🇧🏴󠁧󠁢󠁥󠁮󠁧󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁳󠁣󠁴󠁿🇮🇪🇺🇸⛽️🛢️⚙️🧰💪
Post #812705 30th Jan 2020 2:19pm
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ior



Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10
England 2007 Defender 90 Puma 2.4 XS CSW Caledonian Blue
The brand new OEM EGR valve is literally 3 days old so it can't be that.
Post #812707 30th Jan 2020 2:32pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20348
United Kingdom 
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. $W33T $0U7H3RN $UG4R
🇬🇧🏴󠁧󠁢󠁥󠁮󠁧󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁳󠁣󠁴󠁿🇮🇪🇺🇸⛽️🛢️⚙️🧰💪
Post #812730 30th Jan 2020 5:08pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17372
United Kingdom 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.
Post #812743 30th Jan 2020 6:17pm
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ior



Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10
England 2007 Defender 90 Puma 2.4 XS CSW Caledonian Blue
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
Post #812812 31st Jan 2020 8:59am
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ior



Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10
England 2007 Defender 90 Puma 2.4 XS CSW Caledonian Blue
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 Smile





Post #814209 8th Feb 2020 6:30pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17372
United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Excellent news, well done. Thumbs Up
Post #814224 8th Feb 2020 8:42pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20348
United Kingdom 
Blackwolf knows his stuff. 👍🏻👍🏻 $W33T $0U7H3RN $UG4R
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Post #814230 8th Feb 2020 9:06pm
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expatRob



Member Since: 24 Feb 2015
Location: Frankfurt
Posts: 58
Germany 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?
Post #817797 1st Mar 2020 8:36pm
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ior



Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10
England 2007 Defender 90 Puma 2.4 XS CSW Caledonian Blue
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.
Post #817864 2nd Mar 2020 9:30am
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Bish



Member Since: 11 Nov 2008
Location: Hungerford
Posts: 427
2002 Defender 90 Td5 XS CSW Java Black
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?
Post #818320 5th Mar 2020 5:22pm
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ior



Member Since: 30 Jan 2020
Location: Suffolk
Posts: 10
England 2007 Defender 90 Puma 2.4 XS CSW Caledonian Blue
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)
Post #818548 6th Mar 2020 7:47pm
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