Fiat Ducato failed emissions test, black smoke and limp mode

[MotherTrucker]

Hi everyone, I'm new here, I bought my first Fiat Ducato motorhome (2011 Multijet 2.3) a little while ago and now I'm having trouble sorting out an issue with it as it failed the emissions on its MOT. It belches out black smoke on revving up and it wont rev over 2750 so it seems its in limp mode. This forum has been really helpful and having read a lot of posts about this I've tried the following so far:

OIl change
Checked fuel cap seals properly
Redex
New air filter and fuel filter (no mice in there!)
Checked OBD for codes, there are none
Looked for DPF, cant see one so I assume its Euro 4
Removed and cleaned MAF sensor
Checked inlet pipes for blockage
Removed the vaccum solonoid for the EGR and tested, its seized, new one on order
Removed throttle and cleaned it up (it was quite clean anyway, also descovered an EGR blanking plate there)
Replaced MAP sensor (as I mullered it whilst removing it to clean it)
Checked intercooler and hoses, they all seem ok
Gone in with WD40 all round the electrical connectors in the engine bay


I'm now worried it might be the turbo, I was planning on checking everything then trying an italian tune up but want to make sure I'm not doing more harm than good if its overfuelling. Has anyone got any other ideas?

Oh, and from the service book all 4 injectors were replaced recently so I figure its less likely to be them?

I'm hoping someone here might give me some pointers as Im feeling a bit at a loss now, I love a bit of mechanics but feel defeated now! I've gone from thinking its air intake to EGR to intercooler etc etc and nothing seems to make a difference. I've ordered the MultiECUScan software, just waiting for it to turn up.

Thanks in advance!

 

[eurajohn]

When the injectors were changed did the proxi alignment get done???

 

[Figaro]

Can't help but

 

[Phill D]

hi and welcome,

wait until the Multiecuscan is loaded and familiarise yourself with it in offline mode. then read the codes and see what comes up.

no point in guessing, their inveriably incorrect.

good luck.

ps; the muliecuscan software is a straight download but you will need the correct donle for the obd2 and your van model / year.

 

[Lenny HB]

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[f6c]

Welcome aboard

 

[WillH]

Could be the fuel throttle body , we've had had no black smoke since having a new one fitted.

 

[Nanniemate]

Hi everyone, I'm new here, I bought my first Fiat Ducato motorhome (2011 Multijet 2.3) a little while ago and now I'm having trouble sorting out an issue with it as it failed the emissions on its MOT. It belches out black smoke on revving up and it wont rev over 2750 so it seems its in limp mode. This forum has been really helpful and having read a lot of posts about this I've tried the following so far:

OIl change
Checked fuel cap seals properly
Redex
New air filter and fuel filter (no mice in there!)
Checked OBD for codes, there are none
Looked for DPF, cant see one so I assume its Euro 4
Removed and cleaned MAF sensor
Checked inlet pipes for blockage
Removed the vaccum solonoid for the EGR and tested, its seized, new one on order
Removed throttle and cleaned it up (it was quite clean anyway, also descovered an EGR blanking plate there)
Replaced MAP sensor (as I mullered it whilst removing it to clean it)
Checked intercooler and hoses, they all seem ok
Gone in with WD40 all round the electrical connectors in the engine bay


I'm now worried it might be the turbo, I was planning on checking everything then trying an italian tune up but want to make sure I'm not doing more harm than good if its overfuelling. Has anyone got any other ideas?

Oh, and from the service book all 4 injectors were replaced recently so I figure its less likely to be them?

I'm hoping someone here might give me some pointers as Im feeling a bit at a loss now, I love a bit of mechanics but feel defeated now! I've gone from thinking its air intake to EGR to intercooler etc etc and nothing seems to make a difference. I've ordered the MultiECUScan software, just waiting for it to turn up.

Thanks in advance!

Sounds like a turbo replaced mine but I'm no expert

 

[Landy Andy]

I would guess, from my experience, that your EGR valve is stuck open. That way you loose the boost and black smoke on acceleration. If left too long it will kill a turbo, as will not work in balance. The van will be oblivious to a failed EGR as there is no detection, or sensor on it, it just assumes it is working. The only way to know is to physically test it.

 

[HKF]

I can't help but..............

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[dunnah01]

Black smoke us usually over fuelling so don't worry about turbo or exhaust side. I'd double check the MAF values when you get MES to make sure inlet values make sense. They are notoriously hard to clean so may still be giving bad signals to the ECU. If that checks out OK then check the turbo actuator is operating properly. If that's a bit odd then check the solenoid valve for vacuum leaks

 

[MotherTrucker]

Aw thank you for the welcomes! and all your replies, some good advice there.

eurajohn, The injectors were changed by a previous owner, I only know as I see it in the service book. It was running fine when I got it a year ago so I'm guessing they were fine.

PhillD, ah I'm awaiting it but I'm running out of time in my 10 day MOT retest window so trying to fix it, plus were supposed to be in Devon, have a pitch booked

WillH, I did remove and clean the throttle body, seemed ok.

Nanniemate, god I hope not! But this is what I fear, I cant do that and its expensive isnt it.

Lady Andy, I found an EGR delete plate when I dismantled the throttle body (and left it in for now) so I'm ruling out the EGR as if it was stuck open the gases couldnt get in anyway.

dunnah01, The solonoid valve was duff, which I originally thought was the problem, but then I found the EGR delete. I've now closed off the vaccum tubes and ruled out the EGR system.

So he plot thickens today, last night I thought I'd just sanity check the MAF and unplugged it and the smoke stopped, so off I went this morning to buy a new MAF thinking I'd solved it, fitted it, but still the same problem! Damn it. So I gues thats telling me it is an overfuelling problem, as when I unplug the MAF and ECU sets the injection to defaults I think when you unplug it? The smoke disappears but limp mode remains. But its not the actual MAF thats the problem as a new one doesnt fix the smoke or the limp mode, still no codes from my cheapy OBD reader and no effect when I run the clear codes command on it.

I'm guessing other sensors could be the problem now, but the MAP has already been replaced... are there any more for air intake?

I did use proper Bosch MAF and MAP sensors no the cheap ebay ones. Scratching my head now as I thought Id cracked it!

 

[MotherTrucker]

Oh, dunnah01, by turbo actuator, did you mean the waste gate? I checked the linkage, and its attached as it should be, couldnt move it by hand though

 

[eurajohn]

Reason I asked about proxi align, was that a few years ago on a Peugeot 307 I had, it had a problem when a couple of injectors went bad and it was smoking like no tomorrow, bought and fitted the 4 new injectors and it was better but still smoked, anyway long story short someone that knew said when fitting new injectors the ECU needed to know new ones had been fitted, he had the necessary software (worked at a Peugeot garage) did the align and it was like a new car.

 

[TheBig1]

I know of a 2.3 van that had similar symptoms that 2 garages could not fix. An auto electrician traced it to corroded pins on the ecu causing overfueling.

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[dunnah01]

Oh, dunnah01, by turbo actuator, did you mean the waste gate? I checked the linkage, and its attached as it should be, couldnt move it by hand though

The solenoid valve controls the wastage actuator so if you've blanked them all off as part of the egr delete then this may be causing your over fuelling?

 

[Landy Andy]

The solenoid valve controls the wastage actuator so if you've blanked them all off as part of the egr delete then this may be causing your over fuelling?

Are you sure about that dunnah01 ?
I’m trying to remember when I’ve fitted new turbo, and think that EGR solenoid is separate to anything else.

 

[dunnah01]

Are you sure about that dunnah01 ?
I’m trying to remember when I’ve fitted new turbo, and think that EGR solenoid is separate to anything else.

My bad - I was talking about the vacuum pipe to the turbo control solenoid mounted on the front of the scuttle panel

 

[Landy Andy]

Do you know if you have the newer or older type of throttle body on the engine?

The old ones fail, and the motor that works them can get seized. But the flap only has a very weak spring to return it to the open position. If your spring is weak, then this could get sucked closed on heavy acceleration. I assume your van has had its EGR mapped out, otherwise you throttle body would close on EGR activation.

 

[PaulandChrissy]

Have you checked for air leaks in the air intake between the turbo and the inlet manifold. If you have a leak to atmosphere tha quantity of air flow registered will be high. This will lead to over furling. Easy way to check is get someone to rev the engine while you listen around the ductwork for a hiss of leaking air.

PaulandChrissy

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[The Wino]

As a very basic mechanically minded person the conclusion I come to after reading all the answers is find a mechanic by recommendation and take it there!

 

[Jev88]

Helped a friend with similar symptoms but on a diesel car - EGR clogged meant very poor use of fuel, sometimes smoke and occasional rough engine and limp mode.
Blanking plates are often associated with bad emissions - no surprise as the engine is designed to have a EGR.

 

[TerryL]

This is going to sound silly.
Are your reversing lights working? The power supply for the MAF comes off the reversing light circuit (why Fiat?) so if the fuse blows (guess how I know?) the vehicle goes into limp mode. Your mention of MAF reminded me.

I assume you have the engine warning light on? Be very strange if the van is in limp mode and the light isn't on.

 

[beeza]

sounds like diesel bug that will cause black smoke with no lights on the dash, its getting worse since the interduction of bio in diesel fuel
it can grow quickly in the cheeper (supermarket) fuels that don't have the additives in It grow's when you have a not full tank of fuel and condensation forms inside the fuel tank

 

[The Wino]

sounds like diesel bug that will cause black smoke with no lights on the dash, its getting worse since the interduction of bio in diesel fuel
it can grow quickly in the cheeper (supermarket) fuels that don't have the additives in It grow's when you have a not full tank of fuel and condensation forms inside the fuel tank

I'm not sure the bit about supermarket diesel being more prone to diesel bug than others is true. It is due in part condensation in tanks I would have thought that the places with the freshest diesel will be places with a high throughput like supermarkets.

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[Tony50]

What I advise is take it to a reputable diesel repair specialist or Fiat dealer don't guess it could cost more by guessing they will probably had this problem loads of times ok their hourly rate may seem extortionate, but cost of guessing can be more expensive, get a quotation not a estimate if they are willing to give you a fixed quotation.

 

[Tricky Dicky]

Hi everyone, I'm new here, I bought my first Fiat Ducato motorhome (2011 Multijet 2.3) a little while ago and now I'm having trouble sorting out an issue with it as it failed the emissions on its MOT. It belches out black smoke on revving up and it wont rev over 2750 so it seems its in limp mode. This forum has been really helpful and having read a lot of posts about this I've tried the following so far:

OIl change
Checked fuel cap seals properly
Redex
New air filter and fuel filter (no mice in there!)
Checked OBD for codes, there are none
Looked for DPF, cant see one so I assume its Euro 4
Removed and cleaned MAF sensor
Checked inlet pipes for blockage
Removed the vaccum solonoid for the EGR and tested, its seized, new one on order
Removed throttle and cleaned it up (it was quite clean anyway, also descovered an EGR blanking plate there)
Replaced MAP sensor (as I mullered it whilst removing it to clean it)
Checked intercooler and hoses, they all seem ok
Gone in with WD40 all round the electrical connectors in the engine bay


I'm now worried it might be the turbo, I was planning on checking everything then trying an italian tune up but want to make sure I'm not doing more harm than good if its overfuelling. Has anyone got any other ideas?

Oh, and from the service book all 4 injectors were replaced recently so I figure its less likely to be them?

I'm hoping someone here might give me some pointers as Im feeling a bit at a loss now, I love a bit of mechanics but feel defeated now! I've gone from thinking its air intake to EGR to intercooler etc etc and nothing seems to make a difference. I've ordered the MultiECUScan software, just waiting for it to turn up.

Thanks in advance!

Hi everyone, I'm new here, I bought my first Fiat Ducato motorhome (2011 Multijet 2.3) a little while ago and now I'm having trouble sorting out an issue with it as it failed the emissions on its MOT. It belches out black smoke on revving up and it wont rev over 2750 so it seems its in limp mode. This forum has been really helpful and having read a lot of posts about this I've tried the following so far:

OIl change
Checked fuel cap seals properly
Redex
New air filter and fuel filter (no mice in there!)
Checked OBD for codes, there are none
Looked for DPF, cant see one so I assume its Euro 4
Removed and cleaned MAF sensor
Checked inlet pipes for blockage
Removed the vaccum solonoid for the EGR and tested, its seized, new one on order
Removed throttle and cleaned it up (it was quite clean anyway, also descovered an EGR blanking plate there)
Replaced MAP sensor (as I mullered it whilst removing it to clean it)
Checked intercooler and hoses, they all seem ok
Gone in with WD40 all round the electrical connectors in the engine bay


I'm now worried it might be the turbo, I was planning on checking everything then trying an italian tune up but want to make sure I'm not doing more harm than good if its overfuelling. Has anyone got any other ideas?

Oh, and from the service book all 4 injectors were replaced recently so I figure its less likely to be them?

I'm hoping someone here might give me some pointers as Im feeling a bit at a loss now, I love a bit of mechanics but feel defeated now! I've gone from thinking its air intake to EGR to intercooler etc etc and nothing seems to make a difference. I've ordered the MultiECUScan software, just waiting for it to turn up.

Thanks in advance!

Hi Mother

Hi everyone, I'm new here, I bought my first Fiat Ducato motorhome (2011 Multijet 2.3) a little while ago and now I'm having trouble sorting out an issue with it as it failed the emissions on its MOT. It belches out black smoke on revving up and it wont rev over 2750 so it seems its in limp mode. This forum has been really helpful and having read a lot of posts about this I've tried the following so far:

OIl change
Checked fuel cap seals properly
Redex
New air filter and fuel filter (no mice in there!)
Checked OBD for codes, there are none
Looked for DPF, cant see one so I assume its Euro 4
Removed and cleaned MAF sensor
Checked inlet pipes for blockage
Removed the vaccum solonoid for the EGR and tested, its seized, new one on order
Removed throttle and cleaned it up (it was quite clean anyway, also descovered an EGR blanking plate there)
Replaced MAP sensor (as I mullered it whilst removing it to clean it)
Checked intercooler and hoses, they all seem ok
Gone in with WD40 all round the electrical connectors in the engine bay


I'm now worried it might be the turbo, I was planning on checking everything then trying an italian tune up but want to make sure I'm not doing more harm than good if its overfuelling. Has anyone got any other ideas?

Oh, and from the service book all 4 injectors were replaced recently so I figure its less likely to be them?

I'm hoping someone here might give me some pointers as Im feeling a bit at a loss now, I love a bit of mechanics but feel defeated now! I've gone from thinking its air intake to EGR to intercooler etc etc and nothing seems to make a difference. I've ordered the MultiECUScan software, just waiting for it to turn up.

Thanks in advance!

Hi Mother Trucker I had the same they told me it was turbo then someone on M H F .said Westgate spayed W G with W d 40 a few times then just moved bar a little bit .that was 4 years ago i do spray once a month with dry lubricant. Good luck. Trickydicky.