Black smoke, limp mode, p0299 and p2562

[1661lukeb]

Hi all,
Got a puzzling one for me and I'm really hoping someine can help me.

So, a few months ago I brought a second hand van. On the way home I noticed black smoke from the exhaust and then when I got onto the motorway the engine light came on and I entered limp mode. I went to the garage the next day and the above codes were given where I was adviced that a new turbo was needed. A week later and £1300 out of pocket I collected the van and within 5 minutes exactly the same issues as before were back. I went back to the garage and they checked it over for the day and then told me that the intercooler needed changing at a cost of £300. I lost faith in them so started searching online where I found lots of advice on things to check so I had a friend who is a mechanic go over them today but nothing is standing out to be at fault. Here is what's been checked so far that he's told me he has done

Visually checked all boost pipes and pressure tested some of the main ones

Checked the "y" connector towards the top of the engine

Swapped the turbo solenoid with the egr one to see if the fault changed

The actuator was checked and is still moving

I think I can rule out the turbo lol

The mechanic said he's confused because there is boost and it seems to really kick in around 2700 rpm but still enters limp mode when you cruise around 60mph in 5th or 6th gear but the black smoke is always visible and quite thick. He did say that there is signs that the dpf has been cut open and re welded.

Now here's the interesting part. The van is a Toyota proace (doesn't seem to be very many proace forums) the engine code I've been told from the dealer is "Dw10cd 4wz" 128bhp.

I'm really hoping someone can help before the van has a rear end accident.

Thanks.

[Huskyxantia]

Sounds like the dpf system has come to the end of its service life and possibly the cat too, which can be sort of tested in a way of a little hard driving and some rattling sounds like stones rattling from below the van, i dont have a van sold mine a while back , but the symtoms you have posted are pretty much the same as the dpf & cat system on cars and im sure somewhere on here there may be other posts regarding this, as i recall when the cat breaks down it will throw the limp mode up as it cant handle the presure going through the honey comb due to the damage, if im wrong hopefully someone else might pick this up MattBLancs is pretty good on here he might shed some more light on things , best to you , hope you get things sorted .

[1661lukeb]

Thanks husky for the reply. Would the dpf and cat throw up these codes. I'm presuming that they may come up because they are causing e everything to back up through the system and to the turbo eventually. It's very strange as I took it out again today and there is definitely still boost and pulls well up until 72 when limp mode kicks in, albeit the trail of black smoke behind me.

[Stickyfinger]

Black smoke is normally a sign over to much fuel, that WILL damage you CAT and DPF.....

[GiveMeABreak]

Thanks husky for the reply. Would the dpf and cat throw up these codes. I'm presuming that they may come up because they are causing e everything to back up through the system and to the turbo eventually. It's very strange as I took it out again today and there is definitely still boost and pulls well up until 72 when limp mode kicks in, albeit the trail of black smoke behind me.

I hate to say this, but you may possibly have bought a lemon.

There should be no black smoke with a DPF fitted. The alarm bells are ringing and this to me indicates that the DPF has possibly been removed and the van 'moved -on'.

Have you or your mechanics checked to see if there is any suspicious area around the DPF casing indicating it has been tampered with? You really should check this before spending out any more on parts that may have nothing to do with the issue.

[1661lukeb]

Yes the dpf has been cut open and rewelded. Sorry I did write that in my opening question and you may have missed it. Someone has mention that it may need a new dpf and cat. Is that the case. Sorry I'm now very mechanically minded. With it being such an expensive part Its hard to splash out on that not knowing if it will be the cure.

[GiveMeABreak]

I did miss that, but just seen it in the later paragraph, sorry. So that's why you are getting black smoke, and it'll be an MOT fail for sure. The people that do this are lowlifes in my opinion - leaving all the expense and hassle to the unsuspecting new owner.

There's no way round this, except getting a DPF / CAT (depending on what has been butchered) and getting the engine ECU properly reconfigured.

You may have other issues of course specifically related to fuelling, but it won't help the diagnosis with these elements missing. I'm assuming it was a private sale, so no comeback, but if a garage, I'd hand it back as you've been sold a vehicle not legally entitled to be on the road.

[1661lukeb]

Yes it was a private sale. Very low move when most people won't get under the car to have a look at things like that. I'm also pretty mad at the garage because I'm now thinking the 1300 I spent on a new turbo may not have been the issue and that money could have been spent on a new exhaust system.

Sorry just to clarify in your opinion could the cat/dpf throw out those codes because it's not letting the turbo do it's job properly.

Just looked at the mot history online and saw it failed an mot on emissions and miraculously passed a week later. Presumably this is when the dpf butcher got his hands dirty.

[GiveMeABreak]

Highly likely to be the case. All it probably would of needed was a deep clean.

Pop your VIN up for me and I'll take a look, as I'll need to match the codes to the specific engine management system fitted. Please post your VIN in full without spaces - it will be automatically masked from public view after submitting your post & will only be visible to staff.

[1661lukeb]

The vin number is YARXUAHZ8DZ066709

[GiveMeABreak]

I've just realised this is a Vauxhall / Opel vehicle, and we don't provide specific help for these, despite having similar engines / components, so I can't provide the exact fault code descriptors, but I cab refer you to the faults for PSA vehicles, here:

P0299

and here:

P2562