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Discussion Starter #1
2002 KIA Carnaval 2.9 Tdi. Automatic, 153,000 kilometres.

Whenever I accelerate I get a puff of BLACK smoke from the exhaust (normal driving the exhaust is clean). If I hold my hand under the exhaust and the wife presses on the accelerator I get dry sooty deposits on my hand.

Any ideas ?????? :(
 

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Assuming the car has been serviced recently ( air filter etc ) and it runs okay otherwise wait till the fuel tank is low and add a diesel injector cleaner into the fuel tank.
A whole bottle into the tank will give the best results then see how it goes.

Highlander.
 

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Discussion Starter #4
Thanks guys,

I took the car to the dealer for a computer diagnostic, that came up with "Zip".

The problem seems to be getting worse with low power when the engine is cold .............. damn thing hardly moves until the engine is warm. I replaced the Air Filter last August so I doubt it's that. I ordered a new fuel filter today 'cos that might be dirty.

How difficult is it to get the injectors out? There's a local garage that will refurbish them for me.

I heard all kinds of horror stories but the car only produces this black smoke with an rpm change otherwise it'll still do 160 Km/Hr (100 MPH) no bother.:confused:
 

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Sentech,
I recall some threads in the Carnival and Sedona forums where people have removed injectors. Problems are getting them out and a visit to kia may be necessary to get them programmed if they are replaced with new ones. Try using the search threads facility on the forum.
Highlander.
 

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Discussion Starter #7
So far I've changed the Air Filter (old one was 6 months old), the fuel filter, the Oil filter (6 litres of Mobil 1 fully synthetic 10W 30 plus one litre of Slick 50).

I tipped injector cleaner into 1/2 tank of fuel and me the missus and the rugrat just got back after a 350 km drive thru NL/ Be/ And Germany.

We ran the tank almost empty then filled up with 60 litres of fuel. Apart from a marginal performance increase the black smoke is still there.

A disturbing thing I have noticed is oil spits out of the dipstick hole on tickover (with the dipstick removed) this indicates an over pressuized sump (loss of compression). Strangest thing is this car will start in -18C first crank and cruise the autobahn at 160km/hr (100 MPH).

The thick Black smoke occurs only when pulling away or on kick down, the rest of the time it's not there.

Chris
 

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Discussion Starter #8 (Edited)
The last Kia agent was in the Netherlands (Black smoke is normal from the 2.9 TDi) ................ Yeah Right !!!!!!!!!!!

I took it to a German Kia agent today, apparently the problem is the EGR system (Exhaust Gas Recirculation). Seemingly this malfunction causes the fuel pump to deliver too much fuel on acceleration.

The guy has offered a patch up repair for 80 euros or a full blown repair for 750 euros.

I'm visiting UK next week so I'll probably take the cheap option till I get back next month.

Chris:)
 

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Discussion Starter #9
Got a result .............. finally !!!!!!!!!!!

The ECM (Engine Control Module) is defective, the EGR (Exhaust Gas Recirluation) solenoid isn't opening. This affects the control of the Waste Gate on the Turbocharger.

To cut a long story short, the garage disconnected the EGR solenoid and fixed the waste gate partially open as a temporary repair.

The Black Smoke has stopped and the acceleration is great, bit of a lumpy tickover but I can live with that for a couple of weeks.

Just thought I'd add this post in case someone else finds themself with Black smoke and no apparent reason for it.

Cheers Chris
 

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Just read your post as I am facing a 2.5 black smoke problem too. Did you notice any power loss that accompanied the black smoke? My Sorento has sat for about 4 months and now I need to get it through the registration process, but I am putting out way too much smoke. I am not pulling any codes and no engine lights. I have plenty of power. thanks for any help.
 
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