T5 Tdi 2.5, 120k kms, bad smoking

[Eddie74]

Hi vee dubbers,
I'm new to your site, so apologies if i am not following the rules quite right.

I have a 2007 T5 2.5l tdi transporter LWB which started out life as an ambulance. I've owned it for about 2.5 years driving daily. Over last 12 months, the cold start has become worse and exhaust smokes grey sometimes black. My mechanic has had injectors cleaned, performed a leakdown test (apparently) and replaced Egr valve (?) and other temp sensors. He also pergormed a basic adaption to Ecu which initially made a huge difference. I don't know whether vehicle is chipped or not. However over weeks if driving the symptoms return.

Can anyone recommend a trusty VW mechanic in sydney area who will know how to fix this problem once and for all? Also cruise control switch doesn't respond most of the time.

Many thanks for any advice.

Eddie

[Sunny43.5]

I know its a fairly obvious thing has the air cleaner been changed ?

[Eddie74]

The air cleaner was changed about 6000 kms ago During major service, but thanks for the prompt i will check its condition. Nothing is obvious to me! Thanks.

[Umai Naa!!]

The EGR is an obvious common fix, but not in this case, it seems.

Other things to check include cracked cylinder head (Google this one), glow plugs, and cracked/broken exhaust manifold at number 1 cylinder.

Does the vehicle log any fault codes?

[Eddie74]

I'll have to get mechanic to scan for fault codes, as I don't have the diagnostics kit. The exhaust manifold was changed about 15,000 Kim's ago, at the same time as water pump.

Could you suggest a good mechanic in Sydney? Also, can the glow plugs be easily accessed for inspection? I can do a bit of investigation myself but am a bit nervous of creating carnage.

Another characteristic I noticed is that on idle with aircon running smoke is worse.. With aircon off it is less bad.

Thanks for your advice.

[Umai Naa!!]

The glow plugs are buried under the intake manifold. This will have to come off to remove them. To do that, you'll have to put the front of the vehicle into 'service mode' ie, the carrier module for the radiator, coolers, headlights, etc slides forward a few inches.