CLS 320 CDI - OM642 Engine smoking

[bestlap]

Hi from Bulgaria Europe , I'll try to briefly describe the movie I'm in and I'd appreciate any advice and guidance. The engine is 3.2 CDI 224 hp om642. The problem is that when it warms up over 50 degreese, a lot of smoke starts to come out of the exhaust and the car does not burn oil or antifreeze. When I say that nothing is on fire, it really is so for a mileage of 3500 km, the oil is 2 mm below the maximum where it was on the day of calculation and the antifreeze is exactly at the maximum and is clear as a tear, I check it every 2-3 days. The car has had the DPF and catalytic converters removed by the previous owner.I thought they didn't remove the software DPF and I went to a mapper and he said everything was ok. The cables are disconnected at the DPF and at the front at the catalyst.I had him download a clean software and he removed them to make sure everything was concrete there we did that to no avail.The pressure in the rail is 240 bar when idle.Then I read that they have a problem with the crankcase ventilation, I also changed the 2 valves, the plastic one from above and the one that rests on the camshaft and has an aluminum housing. I also removed the intercooler to see if there was any oil in it and it was absolutely clean with no oil in it.Again without result, then I moved the crankcase ventilation outside and blocked the hole of the swallow, I went like this for 300 km. and I felt the hose was perfectly dry.I checked the turbo and it has no clearances and no oil front and rear. Then it was time for nozzles, I removed the 6 nozzles, took them to a Bosch stand, the 4th one came out that something was wrong and he liked the values of 100% load, but the person said that he could not smoke because of this, but I took 1 nozzle from a friend I took it again to hang it on the stand, he said it was great and I put it in the place of the one that is not ok, I have not gone to have it adapted, tomorrow I will go to the person with the star diagnosis, but the smoke is still the same without change. I have no idea where to go with the solution to this problem anymore.Both fluids do not disappear and it smokes dangerously, I am ashamed to drive it. Starts perfectly both hot and cold and the engine runs super smooth, but smokes a lot. Now a person advised me to take 6 nozzles from another car and put them for a test, because on the bosch stand they did not heat up as much for their short test of 3-4 minutes as on the car and it is possible that if they heat up more then it will cause a problem. Because in the morning when I start the car and when I drive it out of the garage and it runs for 3-4 minutes it doesn't smoke a gram, but when it warms up it starts and when I give it gas 3-4 times up to 3000 3500 revolutions it clears and after a while when I drive it and stop at a stop and behind me come clouds. I put 6 solid nozzles from another cls 320 cdi and the problem remained the same.Here is a video with warm engine >> https://drive.google.com/file/d/11jgxIAG25aPdeDPVO-mk1THdHMuCDD3w/view?usp=share_link

2- https://drive.google.com/file/d/1uq_yWjvfxUmHh1mareJ1IfwEtypGfax-/view?usp=share_link

 

[DSK]

No doubt the experts will be along soon to help you, but the white colour of the smoke would suggest injector/fuel related issue causing incorrect burn.

Is there any smell to the smoke as well as the white colour?


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[Uncle Benz]

You have used a translation program, and it’s made your post a little difficult. Does it only smoke after an extended period of idling?

 

[bestlap]

Uncle Benz - yes i used google translate. It starts to smoke shortly after it warms up /over 60-70 degrees/ no matter if it is working on idling or driving.​

DSK-The smell is pretty bad, it's not like oil, it's like diesel. But the nozzles have been checked on a stand and I have already tried with other nozzles from the same car and the result is the same, it smokes again.​

 

[Uncle Benz]

Dripping injectors are common at this age point. The Blue efficiency injectors don’t suffer the same problem. I’d be suspicious they are dripping, despite the fact you’ve had them tested. Did you specifically ask them to check for dripping? Also, I’ve had problems with reconditioned injectors. Automarine Diesels in Portslade do all my injector testing. They tell me that these particular injectors cannot be reconditioned reliably, and new injectors are the best fix. You can buy service/exchange injectors from Mercedes quite reasonably priced. When you receive them they are brand new units.

 

[bestlap]

Yes, the nozzles are tested for leakage, their electrical part also under load.But as I said, I took a set of nozzles from another car that doesn't smoke, I put them in my car and the car smoked again. By entering the codes of each nozzle according to the cylinder on which I installed it.

 

[Uncle Benz]

How many miles on the engine?

 

[Uncle Benz]

Other possibilities, overfuelling because of bad thermostat, bad coolant temperature sensor, bad ambient air temperature sensor, bad intake air temperature sensor, bad MAF. Quite a few other possibilities. Rarer than injector faults, but it sounds like you have eliminated the injectors

 

[bestlap]

Now, speaking of the antifreeze temperature sensor, the last time we looked at it on the diagnostic, we noticed that the water temperature it showed there was 140 degrees, and on my dashboard it showed a little over 80 degrees. Where is this sensor located on the 642 and can I remove the plug for a test run or do I have to buy a new sensor?

 

[Uncle Benz]

Coolant temp sensor is on left hand bank, near glowplug number 5

 

[Doug1234]

All very odd , when coding the injectors are you using the correct cylinder number sequence . .. looking at front of vehicle they go left side 1-2-3 with 1 at front and 3 at the rear then right side is 4 at front then 5 and then 6 at rear near egr valve.
Also the injector codes, when reading them it’s easy to mistake a 5 for an S and number one for an i etc.
I fitted six new injectors to my om642 in my Jeep and it did similar to what you have in your video and ran awful at idle until the injectors were coded to ecu
The fact the cats and dpf have been mapped out particularly the cats is most likely why it’s doing this though because it’s been tuned , which is why the cats and dpf are mapped out. It’s like following an old classic car and smelling fuel because they are running rich partly because of engine design way back then and because they had no emissions monitoring … yours did but it’s now gone so unless the remap is spot on I think you will be getting what you see from the tail pipes until you refit the cat/dpf

 

[alexanderfoti]

Something to consider, with a DPF removed car.

I had one recently that had the DPF and Cat removed (tut tut) and the software solution that was definitely right and definitely had removed the DPF didnt work properly. No fault codes, no limp mode, but the car was stuck in a pseudo regen mode, that started 10 minutes after start-up and caused excessive smoke ad a high idle.

so, I would spend a lot of time checking the software side of it.

If not that, then nozzles, but your videos shows lots of white smoke when revving. My experience of when the nozzles are dripping is that after a couple of minutes idling, it will start smoking white smoke, and then when you accelerate it will clear up until next time. It usually causes loads of smoke even at idle without revving.

 

[mersum1es]

I would also point first bad remapping. Unfortunately that happens a lot, I believe there are recently 'published' several 'bad' programs around net which will not work (though latest have been adblue removing side effect). I think OP should see SDS live data if regen goes on when problems on smoking start.

 

[bestlap]

I have ordered a new temperature sensor which will arrive on Monday.

Doug1234- Yes the nozzles are lined up just like that and then their numbers are entered via star diganose. We checked twice and everything was entered correctly.

alexanderfoti , mersum1es - Yes, I still think the problem is software. But in my country I can't find anyone who really understands these cars. And I'm starting to think that somehow I need to find someone overseas to whom I can send the ECU file from the car to look at.

p.s I also forgot to ask if anyone with the DPF stopped knows if they have the DPF wires removed and the front ones at the catalytic removed too.

 

[ergishapku]

Hi. I have the same issue with my car. It is Cls 320 cdi w219 of year 2006. I have problem with black smoke. I have dpf and cat removed and dpf off in ecu. My service told me I need to start from injectors , intake manifold and then cat. My injectors are tested 2 times and they seem to be good at the test. After that I removed the inlet manifold and tubes , pipes that are in the inlet part of the engine. Refreshed all the gaskets including turbo and oil cooler. Manifolds were totally blocked with carbon and the air quantity was very poor. The car had a little change in the smoke quanity.After that I went to service again. My service told me usually perople remove the dpf but not cat. Dpf is for better emissions but it doesnt have an important role in the black smoke . So I decided to buy a used one cat. Cat is a very important system of the car. Except the smoke filtration from the harmful pieces , it works as a valve to the engine. It conserves a lot of temperature from gases and this is translated to better smoke quantity , quality and better fuel economy. As soon as I will install the cat , I will let you know if the problem exists anymore.