Strange problem with 1.6 HDI - White/Gray Smoke

[RonniN]

First of i would like to apologize, but the car in question is not a Peugeot, its a Volvo, but it does use the DV6 engine from the PSA group, and i really need some expert advice, so i hope i will be forgiven.

Car starts perfectly, no codes, pulls fine below 3200 rpm, but at 3200 all hell breaks loose, and the engine start juddering, loosing rpm's and pouring white smoke out the exhaust, and smells very much of diesel, at 3800 its finished, and engine is running normally again, and smoke is disappearing.

Engine has done 385.xxx km

Car is not in limp, no DTC's, and will restart without any problems at all, idle is nice and steady, not using any coolant, and there is no signs of water in the oil.

Have anyone ever seen that kind of problem before, i am not sure where to start looking, injector maybe ?

Kind regards
Ronni

[EDC5]

I'm not 100% sure but I would consider the possibility of EGR getting stuck open. Does this engine have the air diverter doser to divert air around the intercooler?

[RonniN]

Thank you for the reply, to be honest i am not 100% sure if it has an air diverter, i forgot to mention that EGR has been removed and cleaned, it was a bit sooty, but nothing major.

I can provide a picture if that will help ?

[RonniN]

Pulling the intake of the engine i found this, first picture is the intake port for cylinder 4, and second picture is for cylinder 3, it looks weird that the one on 4 is clean, but 3 is dirty, i would expect all 4 to be equal.

[RonniN]

No ideas on the problem ?

Exactly same problem described here, unfortunately without a solution.
https://www.mini2.com/threads/r56-diese ... ke.354111/

[RonniN]

Okay, even more of the engine is in parts, turbo is leaking oil on the exhaust side, the vanes/vnt are broken and missing parts, PCV valve is cracked and ripped, turbo actuator is leaking.

[GiveMeABreak]

I would also check the injector seals on the engine. It's well known that the injectors can looses and oil can penetrate, turn to sludge and damage the seals, and once the sludge gets in it works its way round the oil chambers and gets into the turbo - once there it can obliterate the turbo.....

Some other info here with pics of this engine:

viewtopic.php?p=650153#p650153

The accepted solution seems to be frequent oil changes, (circa every 6k miles), check the turbo banjo bolt and ensure it has either the modified strainer in, or as some do, remove it completely and just replace the oil regularly, to ensure that turbo isn't starved of oil.

[RonniN]

Injectors are also pulled out, will replace the seals before going back together, injector 1 was leaking, but it got caught in time.

I am replacing the oil feed line, oil pickup, and return line before refitting the turbo, also removing the strainer, it was missing a piece anyway, car had full service history, but i guess a s**t mechanic.

[RonniN]

I am beginning to wonder if im looking at this problem all wrong.

The white smoke has to be a result of the engine stumbling at 3200 rpm, and has most likely nothing to do with why the car is doing as it does.

[RonniN]

Problem solved.

4 "new" injectors, rebuild turbo, cleaned intake, egr, egr cooler pipe, and the car no longer cuts out at 3200.