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Lorryman100

Member Since: 01 Oct 2010
Location: Here
Posts: 2686

The plug has a little lock on it too stop it popping off. I used a screwdriver tip into the recess on the plastic locking clip and pulled up which unlocked the plug and removed it from the EGR. Also do you have a FCR to check what DTC's are logged?

5th Oct 2011 9:07pm

noworries4x4

Member Since: 24 Dec 2010
Location: Newton Abbot Devon
Posts: 1195

Yes i had a small screwdriver in there to release the clip but that plug is not moving sprayed it with wd40 still no joy. Yes i have got an obd 11 reader lead and software on my laptop, but guess where the lead is, back at home in Devon, must learn to carry it with me for times like this, but step son brought his girlfriends VW polo round on Sunday with its enging light on so i used it then to check that out.
As long as it gets there it's going in to the dealers Sat morning, i am just very curious as to what can be making this so smoky with out a missfire or horrendus fuel consumption and apart from the limp home modes tonight its driving and towing ok, not even running hot. strange !! If everything is under control you are not going fast enough.

Every Day 16 MY Discovery 4 Commercial Workshop and Escort Vehicle
Weekends 07MY L322 TDV8 Vogue SE
Series 1 80" 3ltr 6cyl with overdrive
No Worries 4X4

5th Oct 2011 10:02pm

warren

Member Since: 14 Oct 2009
Location: East Lancs.
Posts: 903

2009 Defender 90 Puma 2.4 HT Santorini Black

Hmmm... Big Black has been having a few smokey moments recently too. Very similar situation to yours too. Noticed it a few times driving around town. Nothing as serious as yours sounds though, just noticed a couple of fairly dark clouds in the mirror as I've been driving around - notice it more at night with other cars lights behind.

EGR valve still does the three chucka chucka's, followed by a clunk which I don't think I've noticed before... Like you I also tried to disconnect the EGR, but the plug wasn't up for shifting.

No misfire, loss of power, increase in fuel consumption and most of the time it's fine.... There's a nice soot build up on the back of the mudflap too. Again, I'm not sure if it's always been like that or I've only noticed now I've been paying attention.

5th Oct 2011 11:59pm

chiefstoker

Member Since: 11 Oct 2010
Location: Weston-super-Mud
Posts: 893

Interesting and intriguing reading. Hows your exhaust/particle filter? perhaps its damaged

2005 TD5 90 Hard Top

Beer 'n Sex 'n Chips 'n Gravy

6th Oct 2011 6:18am

Lorryman100

Member Since: 01 Oct 2010
Location: Here
Posts: 2686

Defenders, at the moment anyway don't have DPF's

I am surprised about the EGR plug though, admittedly it was a bitch to get off as the plastic lug is not the easiest to connect with a screwdriver. Though if you persist it will come off, It did take me a few goes initially to get it off as it does feel as if it is welded on.
The main causes for excessive black smoke emitting from the exhaust are:

Brian.

6th Oct 2011 12:07pm

noworries4x4

Member Since: 24 Dec 2010
Location: Newton Abbot Devon
Posts: 1195

Well i had a crap journey home down the M5 Friday night ended pulling onto the hard shoulder 5 times to reset the ecu as it had gone into limp home mode, rest of the time spent tailgateing artics at 55 trying to hide the fact it was me leaving clouds of smoke everywhere.
Saturday morning up to Matfords and good thing at the bottom of Telagraph hill it went in to limp mode again so i left it, and left it running when i got there so the fault was still active.
Me and Mrs No worries had a walk down to the Toyota dealer nearby and she sat down to watch the Rugby (how civalised with a free coffee) while i got all the stuff to service her Rav 4 before the winter.
Back to Matfords to be told that my exhaust manifold has cracked right through in half (that will be the 4th) and it is melting all the loom, and the maf is out of range.
Had a little chat with the forman to note my displeasure as the vehicle was in for service 4thou ago and i complaind about a rattling noise from the exhaust and they replaced the heat sheald shurly would not have taken a rocket scientist to notice the manifold underneath.
Any way no courtesy vehicles with tow bars untill the 25th or i could have a Peugeot 207 on the 17th thats poor, so i have sorted vehicle cover on Tuesday one of my team can pick me up and take me back as we are working local Tuesday, all in all a right royal pain in the arse. If everything is under control you are not going fast enough.

Every Day 16 MY Discovery 4 Commercial Workshop and Escort Vehicle
Weekends 07MY L322 TDV8 Vogue SE
Series 1 80" 3ltr 6cyl with overdrive
No Worries 4X4

9th Oct 2011 10:10am

wslr

Member Since: 18 Jul 2010
Location: Wellington, Somerset
Posts: 581

So what is causing the exhaust manifold to crack? Poor (re)map? Blocked cat? MAF sensor causing poor fueling?

9th Oct 2011 10:16am

noworries4x4

Member Since: 24 Dec 2010
Location: Newton Abbot Devon
Posts: 1195

I tow heavy things all the time i think they cant stand the heat, i have had 2 turbos sieze up as well and numerous heat shelds If everything is under control you are not going fast enough.

Every Day 16 MY Discovery 4 Commercial Workshop and Escort Vehicle
Weekends 07MY L322 TDV8 Vogue SE
Series 1 80" 3ltr 6cyl with overdrive
No Worries 4X4

9th Oct 2011 10:47am

wslr

Member Since: 18 Jul 2010
Location: Wellington, Somerset
Posts: 581

There is a custom stainless steel exhaust company opposite me. Maybe I will mention it to them and see if they can come up with a prototype solution. Fancy being a guinea-pig?

Might take some time though as they are always busy.

9th Oct 2011 11:04am

noworries4x4

Member Since: 24 Dec 2010
Location: Newton Abbot Devon
Posts: 1195

If i was keeping the the vehicle long term yes but as its replacement is going to be 12 plate Mar 12 ive just got to get it through the winter then its being retired to the bosses farm. If everything is under control you are not going fast enough.

Every Day 16 MY Discovery 4 Commercial Workshop and Escort Vehicle
Weekends 07MY L322 TDV8 Vogue SE
Series 1 80" 3ltr 6cyl with overdrive
No Worries 4X4

9th Oct 2011 12:49pm

noworries4x4

Member Since: 24 Dec 2010
Location: Newton Abbot Devon
Posts: 1195

Right tthe Land Rover went into Matfords today, they replaced the exhaust manifold, had to weld the exhaust flange back on the downpipe/cat, on the list was also a maf any way got the vehicle back tonight and got as far as Exeter Airport on the A30 and smoking was back as bad or worse than before, tryed to keep going as the equipment on the trailer was needed for Wed am in Harrow London. I aborted the attempt and will take the Land Rover back in the morning and will try to get something to get the trailer up to London asap to get the lowloader unloaded.
Deep joy !!!! If everything is under control you are not going fast enough.

Every Day 16 MY Discovery 4 Commercial Workshop and Escort Vehicle
Weekends 07MY L322 TDV8 Vogue SE
Series 1 80" 3ltr 6cyl with overdrive
No Worries 4X4

11th Oct 2011 7:39pm

Sockpuppet

Member Since: 17 Sep 2011
Location: Leicester
Posts: 479

Sounds like what I had in my focus. Inlet manifold cracked and it resulted in loads of smoke.

12th Oct 2011 12:18pm

noworries4x4

Member Since: 24 Dec 2010
Location: Newton Abbot Devon
Posts: 1195

Right then smoking update,
When i left home on he Wednesday morning the 90 ran ok all the way up to Exeter it was only once i was on the flat running on the M5 and throttled back to a cruse that the exhaust started smoking badly again, at 1 point i thought it had cured its self and i was going to get up to London late but can't be helped as they say. I turned round took it back to Matfords and fair play i un-hitched the trailer and straight on the ramp, plugged into diagnostics and the ecu would not talk to it. A few goes later turbo underboost fault shown but and a big but the code was not a Defender code so lots of scratching heads.
I had to sort my self out a set of wheels and carry on with the day job, Matfords did not have anything with a towbar so i started to phone round. SHB 4X4 needed over 24hrs to set up an account for credit checks ect, enterprise head office were less than helpfull, Thrifty only do towbar Warriors to the military not to the public so itryed the local office of Enterprise as i know they run the Land Rover assistance fleet, yes they had a Disco 4 in stock with a tow bar, a few hoops to jump through re insurance cover notes ect but soon all sorted.
Back to Matfors to collect my trailer and the 90 was off the ramp and parked up, asked when i migh get it back they said Friday as they found 2 small vacume hoses split sending false signals to something they did not tell me what but the hoses will be in on Friday and i will pick t up on Saturday.
So meanwhile i am floating about in a lovely Disco 4 SV HSE nice !!! not going to wan't to give it back, towes the Ifor a dream so powerfull and smooth, got to admit though towing in central London i certainly noticed it's a lot bigger but the excellent steering lock makes up for that. If everything is under control you are not going fast enough.

Every Day 16 MY Discovery 4 Commercial Workshop and Escort Vehicle
Weekends 07MY L322 TDV8 Vogue SE
Series 1 80" 3ltr 6cyl with overdrive
No Worries 4X4

14th Oct 2011 12:07am

noworries4x4

Member Since: 24 Dec 2010
Location: Newton Abbot Devon
Posts: 1195

I don't want to give the D4 back rather taken with it

If everything is under control you are not going fast enough.

Every Day 16 MY Discovery 4 Commercial Workshop and Escort Vehicle
Weekends 07MY L322 TDV8 Vogue SE
Series 1 80" 3ltr 6cyl with overdrive
No Worries 4X4

15th Oct 2011 9:33pm

warren

Member Since: 14 Oct 2009
Location: East Lancs.
Posts: 903

Haha I get like that whenever I get a courtesy car... Then as soon as I sit back in the Defender it all goes out the window....

18th Oct 2011 1:59pm

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