Boxer 2.2 HDI White Smoke During Regen

[tsmith149]

I'm hoping this might ring a bell with someone. The vehicle is seemingly in good health, no fault codes, runs ok, clean exhaust under start up and usual driving. That is until the van starts an active regen at which point great clouds of billowing white smoke are emitted from the exhaust during acceleration. Once you get up to a steady speed on flat ground the white smoke pretty much disappears but during any kind of acceleration the smoking is extreme. The regens do get up to about 560ish C and they do seem to complete ok.

What I've done so far;

Vaporiser (5th injector) replaced (fuse check, 1ohm through the circuit, initial current draw 13amps settling at about 6.5amps once up to temp).
Fuel dosing pump tested ok.
New EGR valve installed and coded.
DPF differential pressure sensor tested ok.
Injectors professionally tested and 3 replaced and coded.
Glow plugs tested ok.

The vehicle is a 2014 Boxer with the 2.2 ford puma engine, it doesn't seem to be burning oil but I think there could be a small use of coolant (I need to top up 250ml every few thousand miles) not sure but it might be a small radiator leak. The turbo is make boost no problem and as far as I can tell the throttle body closes when necessary.

Nothing that I've tried has made any noticeable difference to the white smoke problem ... anyone got any better ideas??

I was wondering if anybody knows how much diesel is supposed to be collected during the dosing pump actuator test? Diagbox says to collect the fuel from the pump into a graduated cylinder but it doesn't tell you how much volume you should expect.

Many thanks,

Tom

[Sinke]

Hi Tom

I have exactly same issue. It started a year ago after I discovered that DPF was deleted by previous owner( failing MOT emissions test). We've put new DPF, sorted failed egr valve, reprogramed ECU to factory settings(it was remapped when DPF deleted). Within a week it started regen every time it run even from half warm engine. Replaced DPF temperature sensor (blue lead one) and it solved premature regen.
Since then it has exactly same issue as yours. Excessive pungent white/bluish unburned diesel/acidic smelling smoke on every regen. Especially when engine is under the load. On flat open road with gentle pedal push smoke goes away, but as soon as accelerator is pressed it gallows smoke(as when military tanks apply smoke screen).
If during smoky process I press clutch pedal and rev the engine in same time smoke disappear instantly, it only smokes during regen whilst under any engine load
I found that driving it in lower gear with revs 2.5-3k without acceleration it helps burn the smoke away
Fifth injector replaced, wiring checked, fuel dosing pump checked, injectors checked, egr valve checked. All good, no codes either.
It feels that is either overfueling or DPF is not hot enough to burn off regen fuel clean
I'm still looking into what could cause this. I didn't find yet a single garage or mechanic or internet thread that explains this problem. Wherever I go they plug comp in and run diagnostics saying everything is fine
If you do find solution, please let me know, I'll be grateful. Also, I'll upload here if I come across the solution
All the best
Sinisa

[GiveMeABreak]

Have either of you got any fault codes (and bear in mind generic code readers may not work properly)?

[John1966]

Hi Tom

I have exactly same issue. It started a year ago after I discovered that DPF was deleted by previous owner( failing MOT emissions test). We've put new DPF, sorted failed egr valve, reprogramed ECU to factory settings(it was remapped when DPF deleted). Within a week it started regen every time it run even from half warm engine. Replaced DPF temperature sensor (blue lead one) and it solved premature regen.
Since then it has exactly same issue as yours. Excessive pungent white/bluish unburned diesel/acidic smelling smoke on every regen. Especially when engine is under the load. On flat open road with gentle pedal push smoke goes away, but as soon as accelerator is pressed it gallows smoke(as when military tanks apply smoke screen).
If during smoky process I press clutch pedal and rev the engine in same time smoke disappear instantly, it only smokes during regen whilst under any engine load
I found that driving it in lower gear with revs 2.5-3k without acceleration it helps burn the smoke away
Fifth injector replaced, wiring checked, fuel dosing pump checked, injectors checked, egr valve checked. All good, no codes either.
It feels that is either overfueling or DPF is not hot enough to burn off regen fuel clean
I'm still looking into what could cause this. I didn't find yet a single garage or mechanic or internet thread that explains this problem. Wherever I go they plug comp in and run diagnostics saying everything is fine
If you do find solution, please let me know, I'll be grateful. Also, I'll upload here if I come across the solution
All the best
Sinisa

Interested to read this as it ties in with a problem that I've got with my Boxer, You mention the DPF temperature sensor, whereabouts is this located? as I've had a look at mine without success. Many thanks

[GiveMeABreak]

@John1966

Are you aware you still have an outstanding after-sales campaign on your vehicle? I was checking your engine type regrading the sensor location when it flagged up the warning, so I would give Peugeot a call and get it booked in. I can't tell you what the work involves or what it is related to, but it will be free of charge. It may even be related to your emissions issue above ^.

As for the exhaust gas temperature sensors, there are 2 of them.

Standing facing the windscreen, the downstream sensor is on the left side of the DPF exhaust housing on the 'band' that joins the parts.

The Upstream Sensor is located on the top of the exhaust at the very beginning where the main pipe enters the Cat at the 'neck'.

Be aware there are the DPF pressure sensors too.

[John1966]

Standing facing the windscreen, the downstream sensor is on the left side of the DPF exhaust housing on the 'band' that joins the parts.

The Upstream Sensor is located on the top of the exhaust at the very beginning where the main pipe enters the Cat at the 'neck'.

Be aware there are the DPF pressure sensors too.

I'm finding two temperature sensors, one with a blue tail and one with a green. Both are fitted to the DPF itself, I'm not finding anything fitted to the cat other than the atomiser.
Could be I'm just not seeing it, I'm working on the ground under the van, also removed battery tray.
Any ideas what sort of resistance if any that I should find when cold?
Could be that the wiring was damaged when the fifth injector burnt out, as they all run through the same section of loom but I'll check that out next.

[GiveMeABreak]

John if you need the part diagram location / part numbers, I can assist, but please see below:

If you can't already find the info you need on the Forum, we do ask for a membership upgrade for official parts data as we are in turn charged for this. It will cover you for future parts requests for up to 2 years, so excellent value.

If interested, links are below, then pop your VIN up.

A response to your question by a Forum Admin requiring parts or additional information requires you to have made a current contribution (£10 min.) to the Forum.

To Upgrade Your Membership & Donate Click Here For Further Information About Vehicle Parts and VIN Numbers Click Here

[John1966]

Marc
I've donated via paypal
VIN is VF3**************[VIN obfuscated, can be read by forum staff]
Any more info regarding the wiring diagrams, part numbers for sensors exact locations would help.
I'm fairly certain that there are just the two temperature sensors located on the DPF itself,
Wiring to the multiplug behind the nearside headlamp has tested out ok, sensor sitting at 10MΩ when cold

[GiveMeABreak]

Ok, so here here is the parts diagram:

Item (2), Downstream Gas Temp. Sensor, part: 1606611680, £163.08
Item (3), Upstream Gas Temp. Sensor, part: 1606611580, £161.81

The Exit particle filter pressure pipe is shown as (7), part: 1607433880, £17.98
The Entry particle filter pressure pipe is shown at (8), part: 1607433980, £17.98

There are 2 possible wiring diagrams for this vehicle and each has different pin assignments for the exhaust gas sensors, so I'll put both up and you'll have to determine which is which:

1341 : particle filter differential pressure sensor /
1343 : downstream exhaust gas high temperature sensor /
1344 : upstream exhaust gas high temperature sensor /
1320 : engine ECU /

Option 1:

Option 2:

[John1966]

That's really helpful Marc, I'm seeing the sensors on Autodoc, but given the state of post and deliveries in this country at the moment, I'll probably go to Arnold Shark when I'm in Inverness next week, the decision will be, will it be my right arm and leg or my left that I use as payment!! Next challenge is to extract the sensors, might be easier to drop the dpf.

[GiveMeABreak]

Hi John

Good luck with that - I've put up a procedure for the removal and refitting for you along with the torque settings. It can be found in the resources Section here:

Peugeot Boxer III Puma 110 Exhaust Temp Sensor Replacement

[tsmith149]

Hi Tom

I have exactly same issue. It started a year ago after I discovered that DPF was deleted by previous owner( failing MOT emissions test). We've put new DPF, sorted failed egr valve, reprogramed ECU to factory settings(it was remapped when DPF deleted). Within a week it started regen every time it run even from half warm engine. Replaced DPF temperature sensor (blue lead one) and it solved premature regen.
Since then it has exactly same issue as yours. Excessive pungent white/bluish unburned diesel/acidic smelling smoke on every regen. Especially when engine is under the load. On flat open road with gentle pedal push smoke goes away, but as soon as accelerator is pressed it gallows smoke(as when military tanks apply smoke screen).
If during smoky process I press clutch pedal and rev the engine in same time smoke disappear instantly, it only smokes during regen whilst under any engine load
I found that driving it in lower gear with revs 2.5-3k without acceleration it helps burn the smoke away
Fifth injector replaced, wiring checked, fuel dosing pump checked, injectors checked, egr valve checked. All good, no codes either.
It feels that is either overfueling or DPF is not hot enough to burn off regen fuel clean
I'm still looking into what could cause this. I didn't find yet a single garage or mechanic or internet thread that explains this problem. Wherever I go they plug comp in and run diagnostics saying everything is fine
If you do find solution, please let me know, I'll be grateful. Also, I'll upload here if I come across the solution
All the best
Sinisa

Hi Sinisa!

Wow, sounds like our vans were separated at birth. I have an identical story. The van failed MOT due to soot and I discovered DPF had been removed (had I not converted the van into a campervan I would have probably just got rid of it at that point but since I'd done all the conversion work and I wanted to take it abroad I decided to try and make it legit again and replace DPF).

I also had the ECU remapped to what I was told was a standard map. The van started trying to regen (with heavy smoke) on every journey once the map was done even though the DPF was brand new. Once I told the van I'd fitted a new DPF in Diagbox the van stopped trying to regen all the time and now I get between 100-180 miles between regens. The smoking symptoms are absolutely identical to how you described them. You basically have to make sure you're on flat open road with no traffic so you can stick it in 5th gear and drive at a steady 65mph plus, otherwise you're blowing huge clouds of smoke. Accelerating away from lights etc is a nightmare.

A Question for ECU/Mapping Experts Out There
I had my van remapped back to "standard" at an independent tuning company who did not have access to the vans original file, they found a file from somewhere though. I wonder if maybe Sinisa and I have both been given the same file and maybe it isn't quite right for our vans?

Is there a way for us to compare our files if we could get the tuning companies to send them to us? Or at least compare the file names or something like that?

Next question; is this something a main dealer or good Peugeot specialist could potentially solve with the right ECU map?

Cheers,

Tom

[John1966]

Back again!
So since last postings I've had the dpf professionally cleaned, and replaced both egt's in the dpf with OE equipment sensors.

Now I'm getting fault code P2002 7A Particulate filter detected to be absent. (I'm guessing that the ecu will need to be told that it's been replaced?)

Live data on and out for a test drive, temperature and pressure information all seems to be being read ok, so about half a mile from a cold start, tik, tik, tik.... on comes the dosing pump, the atomiser switching on occasionally and the pump switching off for a few seconds before coming back on.

The atomiser has been replaced, primed and coded.

So why on earth is it trying to regen continuously especially as it doesn't even think that there's a dpf on the van???????

[GiveMeABreak]

@Tom: The only way to replace the ECU map I suspect is to have the engine ECU software re-applied at the dealer, which should apply the map as intended for the vehicle. Citroen / Peugeot should be able to clarify.

@ John: Yes, as Tom mentioned in his reply, you need to tell the engine ECU that the DPF has been replaced. I've deleted your other post as it is a duplicate of this one and can lead to duplication and repetition of answers.

[tsmith149]

Thanks for the reply Marc, I'll try contacting a dealer.

Just the other day I performed a scan with Diagbox and discovered a new fault code:

P0423 92 - Atomizer for injection of fuel at the exhaust

Cause - Local
Status - Intermittent
Characterisation of the fault - Internal Fault

As far as I can tell the atomizer is working as it should, it is almost new and draws current (about 6.5A once up to temperature) when actuated. Maybe the ECU has generated this fault code because injection through the atomizer isn't generating quite the EGT temperature increase the ECU expects to see?

Some sort of failure or poor performance in the atomizer could potentially explain the clouds of white smoke. Injecting atomized diesel into the exhaust pipe presumably causes combustion whereas sticking liquid diesel into the exhaust would just makes smoke; kind of like a red arrows display.

Does anyone have any experience of this fault code and what to check out?

As for the temperature sensors I'm planning to pull the out of the DPF and one by one put the tips into a temperature controlled kiln that I have. That way I can check that they are correctly ported and are reading accurate temperatures in Diagbox. Diagbox is confusing in the way it names the two exhaust/DPF temperature sensors. Instead of referring to Upstream and Downstream temp sensors (like the parts list does), Diagbox refers to Cat. converter upstream temperature and Particle filter upstream temperature.

Refering to the diagram posted by Marc above, I think:

Cat. converter upstream sensor = Item (2), Downstream Gas Temp. Sensor, part: 1606611680
and
Particle filter upstream sensor = Item (3), Upstream Gas Temp. Sensor, part: 1606611580
Does anyone know if this guess is correct?

On my van, during regen, the particle filter upstream temperature reading seems to be upto about 100C higher than the Cat. converter upstream temperature.


Sinisa; I checked my ECU software version so if you're able to take a look (or get someone else to take a look) with Diagbox it might be interesting to compare and see if we've got the same file:

Software Reference: 96 917 610 80
Software version: 00 00
Approval reference: 96 668 458 99
ISO Reference: 7507130DF1

Cheers