Td5 making black smoke

[mturri]

A mates Td5 Defender (2006) is making lots of intermittent black smoke.

New fuel pump, new FPR, new injector o-rings & washers. New turbo hoses. Boost pressure as well as other fueling parameters all in good order.

No oil consumption. No significant blow-by. Installed known good injectors then known good ECU, all to no avail. Does it either when cold or warm. Sometimes idles ok, other times smokes right from start up, no clear pattern here. When floored for a while it starts burning clean. Intake manifold and intercooler look clean.

Heavy smoking while idling is usually accompanied by abnormally high cylinder corrections (live cylinder readings jump from +/- 2 to +/- 24) and somewhat rough running (not rough as when running on 4 cylinders, just not smooth). No oil in harness, red plug or ECU. No misfiring whatsoever.

At my wits end... any ideas?

Thinking porous head but may very well be loosing it...

[Blknight.aus]

in no particular order

partially blocked intercooler
collapsing air filter
turbo failing
contamination on the crank angle sensor or the flywheel drillings
bad earth
harness damage
alternator fritzing.
MAF/MAP or ambient air sensor not ranging correctly

[mturri]

Thanks & will keep you posted!

[djam1]

So Mturri what was the problem??

[outnabout]

Hey fellas,

Similar problem with my 130 (2003). Decided to start blowing black smoke after a Tassie to Qld trip in the late December heat.
I'm a light weight when it comes to diesel mechanics and just carry out basic maintenance and keep a close eye on basic operating trends.
How helpful are the diagnostic computers in determining the cause of these sorts of problems?
On another note, the handbrake lever was bloody hot during the trip. I did take it easy to manage the heat but was pretty concerned. The engine temp gauge was pretty constant throughout so I was guessing gearbox/transfer box radiant heat (didn't seem to me that the exhaust was the cause).
I'll have to take it in to the grown-ups for an educated eye to have a look at the poor old girl I think.
Mainly just posted this to stop getting kicked off this brilliant website.
Cheers Fellas

[nedflanders]

Oldie but goodie but have you changed the injector harness?