Black smoke - P0299 - P3008 - P0100 HELP!

[bigtone0777]

I'm having a problem with my 2006 Xsara Picasso 1.6 HDi 90PS that I just can't figure out.

Symptoms are as follows:
1) Sound like an exhaust leak on light throttle
2) Slight loss of power
3) Black smoke when accelerating under load (mainly up hill)
4) Fumes entering through vents when stood still idling for a minute or so
5) Lost about 10 MPG

About every 25 miles or so town driving it throws up the following codes.
P3008 - Manufacturer control
P0100 - Mass or volume air flow A circuit
P0299 - Turbocharger / Supercharger Underboost

I've checked all the boost pipes and changed the intercooler as I thought it had a leak but no change. I've also replaced the exhaust manifold gasket as thought that could be the source of the noise and fumes but again no change. I inspected the turbo while it was off and all looks great but was a little surprised to find there was no gasket between the turbo and manifold so called the dealer and apparently there isn't one although they are available on eBay.

Any suggestions greatly appreciated.

Thanks for reading

[GiveMeABreak]

Do you have the VIN, it’ll help correctly identify the other systems fitted. But I suspect you have the Bosch Injection and the DV6ATED4 92 Engine.

If so, these are the faults descriptors in order of priority: (P0299, P0100 & P3008)
P0299 - Turbocharger pressure signal: Pressure too low in relation to the reference value
P0100 - Flowmeter signal: Air flow not plausible
P3008 - Flowmeter signal: Air flow too strong

You will need to click on these tables to focus and zoom

So follow these in order, P0299 first, then P0100 and P3008 last, looking at the suspect areas. Ignore any reference to Particulate filter and regeneration as you don't have a DPF on this engine if my assumption on engine is correct.

[bigtone0777]

Hi Marc, thanks sharing this information, it gives me something to work with rather than working blind.

The VIN is : VF7**************[VIN obfuscated, can be read by forum staff]********

Tony

[GiveMeABreak]

No worries Tony - confirmed Engine and Bosch variant as above. All those codes I listed are specific to troubleshooting the variable geometry turbocharger fitted to this engine.

[bigtone0777]

I'm working on the Pic again this afternoon trying not to pull too much of my hair out lol

I've removed the air box to be able to inspect it and any vacuum pipes etc that I can see, so far all looks good other than some of the wires on the EGR connector have been rubbed through to the bare wire, not sure if they've been shorting or even if that could be causing my issues but I'll insulate them and put everything back together with a new air filter.

Also from the pic of the EGR would you say someone has blanked it off or does the gasket stick out like that?

Thanks

Tony

[GiveMeABreak]

Hi Tony - Those wires are in a bad shape - well found!

That sure looks like it has been blanked off! There should be nothing sticking out of it like that and it looks to be the wrong shape!

This is a genuine one and as you can see it only has the one curved node - whereas the one in your picture has multiple waves and clearly does not fit. It really shouldn't be sticking out like that as it's a sure fire way of slicing through any other wires surrounding wires (although I appreciate the EGR plug wiring is further back). Whether it has been blanked off or whether it is an incorrect plate fitted will be hard to tell for sure until it is removed though. But whatever the case, it isn't a proper one by the looks of it.

Here is an example of a proper one:

The correct part number for it is 1618AW

Here is a link for example:
https://www.eurofrance.pl/pl/p/Uszczelk ... geot/49693

[bigtone0777]

Thanks for the info Marc! I think I'll leave the EGR alone for now though as if it's been blanked off it must have been mapped out too as I'm getting no codes relating to EGR.
I insulated the wiring to find that it had already been repaired once but it made no difference what-so-ever (which it wont have if the EGR's mapped out) but what I have found is that the vacuum pipe connected to the wastegate is creating vacuum all the time. I took the car for a quick drive with is disconnected and although the car was a bit flat the hissing noise had gone and also no black smoke, connected it back up and back to the original issue. Is this a faulty boost control valve?

Thanks

Tony

[GiveMeABreak]

It is uncommon for these to have boost control errors on the HDI - but the 2009 1.6 Picasso had low acceleration and black smoke issues - the guy suspected the turbo, but then he went to inspect it, the central retaining nut securing the turbo vanes had come off - and had caused the damage as it was constantly getting shredded as it tried to pass through the vanes and stopped the turbo of course. It has lack of power, was unresponsive - have a look - worth checking out:



Richard or one of the others with more expertise on this particular engine may be along to give you some other pointers Tony.

[bigtone0777]

I actually watched that video a few days ago,very interesting.
I my turbo is in great condition unless the veins have siezed as I'm not able to check them without taking the turbo apart. The constant vacuum to the wastegate actuator seems wrong although in my head this would cause an overboost rather than an underboost. The car might have to go to someone that knows what they're doing lol

Thanks again for all your help Marc

Tony

[bigtone0777]

I changed the vacuum converter valve this afternoon but there is absolutely no change what so ever. I'm back to thinking it's a boost leak, possibly from the rigid pipe between the turbo and intercooler flexi hose, I need to figure a way to test it.
I'll update when I've "played" some more

[bigtone0777]

I've had a bit more "play" this morning and with the help of someone holding the throttle open for me (I can't do it from under the bonnet) I've discivered smoke coming from the back of the engine somewhere. The note changes when holding certain revs, I presume this is when the black smoke is present when driving and after turning the engine off you can hear a whistle like pressure leaking from somewhere which then stops presumably when pressure has reduced.
I have recorded two videos, one showing the smoke and the second focusing on the change in engine sound and the whistle but I don't know how to upload them.

[bigtone0777]

Hopefully this will work.

[white exec]

Looking at your listed symptoms, might be a partially blocked exhaust. Diesels don't like back-pressure.
Try dropping the exhaust at a front joint (tie it up so it doesn't fall), so that only the exhaust manifold/turbo/downpipe is connected, and do a test drive with it like that. It will be surprisingly quiet, because the turbo smooths out exhaust pulses. This will confirm whether there is an exhaust restriction issue.

[bigtone0777]

On the 1.6 the cat is connected dirtectly to the turbo so the best I could do is disconnect the back side of the cat from the flexi. I'll do that next and give it a try. I should know just off doing the same stationary test I would guess

[white exec]

You can try that, but you really need to get the cat put aside. If it's a honeycombed ceramic cored oxidation cat, the cores can block up with soot, causing back pressure. Try it anyway.
Stationary test will tell you something; a road test is better to assess how much power is there.