Citroen jumper 2.2 HDI white smoke problem

[MarMar]

Hello,

I have a Citroen Jumper from 2011 with the bad 2.2 HDI 4HU/Puma engine.
Bought it 3 years ago and converted it to camper. Context history/story of the problem:

first winter it only drove short periods during the build (in and out the shed), it also was an imported van and not yet registered, so couldnt hit the road. When ready for the camper and import inspection at the RDW it smoked some black smoke and on the way back it got worse. We put in some cans of injector cleaner and hit the highway. We kept it between 3000-4000 RPM to let it clean itself and on the highway exit the rpms dropped and it stalled with engine light, had to tow it home.

After months of sitting there we finally took out the engine. The crank and rod bearings were shot and on the exhaust cam the little part between vaccuum pump and exhaust cam broke, so that locked up the engine. Bought a kit with: pistons, rods, bearings, crankshaft and also replaced the injectors, glow plugs, distribution chain, high pressure fuel pump with rail sensors. The engine was bored to fit the pistons and was completely checked. The company lost the head and they later claimed they found it again, but I cant prove whether they bought another used one or it was mine.
They replaced valves and seals and got the head flattened.

I assembled the engine myself. Sadly I didnt check the value between top of the piston and top of the engine... I put in a 1.2mm head gasket. Everything turned smoothly and seemed fine. Assembled everything to the right torque values.

With a bit of brake cleaner it fired right up and ran good, It smoked a little, but assumed it was from brake cleaner + new engine that had to run for a while.

It suddenly stopped and it turned out to be water in the ecu (it got in there when the van was sitting outside) I bought a new ecu with bsi and key chip.

Right now it has been sitting for another year, due to lack of time. It still fires up with brake cleaner (not without) and it smokes lots of white diesel smoke (not coolant). The smoke works better than teargas and would kill you if you fire it up in the garage. It runs in limp mode.

I had another dude with diagnostics (autel) come over again and he cant put in the new injector codes, because its in limp. There was a red cross behind the EGR and he couldnt read that one. Maybe its programmed out in the replacement ecu or the egr doesnt work anymore (shouldnt emit white smoke tho)? It has plenty of constant rail pressure (after reading it with delphi and replacing high pressure pump. Dont know the exact value right now, but I remember it being above the needed pressure in the diagram).

I checked engine compression and they are all around 380psi/26 bar. The injectors got tested again by a specialist and they were fine. Checked timing again with the special ford puma tools and that was good. Right now I (and the mechanics) are clueless and the van is still standing there after 3 years. Does anyone know what to check or something to look at?

[moizeau]

I bought my van with a white smoke problem. Smoked and stung your eyes until up to temperature. EGR was knackered. Confirmed by doing an 'actuator test' with Diagbox. Swapped in another, all good.