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Old 22nd April 2017, 09:04   #1
SWTH
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Default ZT CDTi Smoke and Loss of Power

Hi folks, my ZT CDTi suffered a bit of an issue yesterday.

Under some fairly hard acceleration the car stuttered, started blowing loads of smoke out and lost power. I needed to continue my journey so I took it gently and kept an eye on things.

So far I've checked:
Intercooler hoses - appear to be fitted and secure.
Air filter - appears new
EGR - valve is opening and closing

Engine idles smoothly, it accelerates ok but blows lots of black smoke out. No blue or white smoke.

Engine management light wasn't on, but around 80 miles later the engine management light came on, it smoked less and responded better to the throttle.

Any ideas what to check next please?
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Old 22nd April 2017, 09:33   #2
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Well I'm no expert but had a similar cenario when I first got mine. Checked the PCV valve and was found to be blocked solid. Then found that the intercooler O-rings were absolutely shot and was loosing boost pressure. With new o-rings and a new valve, it was fine. Maybe worth checking those first as it's easy.
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Old 22nd April 2017, 10:14   #3
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PCV valve is next then.

The O-rings were done apparently a few weeks ago before I bought it.
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Old 22nd April 2017, 11:05   #4
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i'll second the pcv valve as mine was blocked, but on my car I didn't get rid of the smoke until I replaced the hose from the egr to sensor which was split.
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Old 22nd April 2017, 12:06   #5
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Also worth checking that the flexi to the egr valve isn't split.


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Old 22nd April 2017, 14:47   #6
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Just to clarify you mean the flexible pipe that looks similar to diesel leak off flexi?
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Old 22nd April 2017, 15:29   #7
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Quote:
Originally Posted by SWTH View Post
Just to clarify you mean the flexible pipe that looks similar to diesel leak off flexi?


No, I mean the flexi/ bellows.
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Old 22nd April 2017, 17:09   #8
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Quote:
Originally Posted by SWTH View Post
PCV valve is next then.

The O-rings were done apparently a few weeks ago before I bought it.
The lies the clue, 'apparently'. Check for signs of fresh oil deposit on hose from intercooler to EGR valve, the o-rings need to be viton type ensure they are, that means taking front bumper off so you can have a proper look.

Before doing this check the PCV oil separator is clean and replace it. careful with the return fuel pipe connectors, they have retaining clips which need removing or the connectors are easy to break.
Word of advice, don't trust anyone who tells you the car was serviced, before you bought it, it will not have been. This forum will be your mother and father for the duration. Good luck.
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Old 22nd April 2017, 17:26   #9
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The metal EGR pipe is new.

The intercooler-EGR hose is secure, no recent deposits but the area has evidence of previous deposits.
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Old 22nd April 2017, 17:28   #10
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Also, please check out the intake manifold, especially around the joint seam where the two halves are glued/welded. I had exactly the same scenario two years ago, (documented on here) and it was the inlet manifold that had burst at the seam. Probably due to an earlier owner soaking the manifold in a solvent to clean out all the crud prior to fitting an egr bypass.

I obtained a S/H replacement for £12 on the 'bay' and after a thorough mechanical clean out have not had a repeat 'blow out' since. Full power restored thereafter
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