Volvo v40 1.6D smoking on start up

[E-bmw]

I have a v40 1.6d2 2015 that seems to have an issue that is developing further and is noticeable on start up.

There is grey smoke on start up that clears after a few minutes/miles and also seems to be associated with it being a bit more of an uneven/lumpy idle than that at other times.

I can't say that the "smoke" smells of diesel indicating un-burnt fuel but it does smell REALLY burnt if that makes sense. There is only a very small amount of "breathed" oil in the turbo inlet & the turbo seems to be spinning freely without play in the shaft.

I have also just pulled off a fault code stating "Injector 3 learning at maximum learning" or similar wording.

I am assuming that injector 3 is on it's way out.

I do have second hand spares from my relatively recent engine change and spare copper washers & an injector seat tool.

[K is King]

Ah the good old PSA 1.6 diesel (DV6) used ubiquitously across many marques.......having had this engine now in a Mini and a Volvo and both suffering from smoking, powerloss etc I can tell you where to go looking......

1. Injector failure / leaking
2. Split in the PCV Valve diaphragm
3. Split in the Turbo Intercooler hose
4. Split in the Turbo Intake pipework (Airbox to Turbo to PCV)
5. Failed Turbo intake seal
6. Failed DPF Pressure sensor
7. Clogged DPF
8. Clogged Fuel Filter

First time was in a Mini and I actually gave up on it out of frustration but I didn't check everything on the list above. Second time round with the FIL's Volvo I took my time and replaced all the above and cleaned the DPF. Touch wood the engine is now running like it should.

The hoses and seals are all readily available on eBay / Amazon / Motor factors just don't restrict your search for 'Volvo' and and up paying a premium. I've used a combination of pattern parts and originals but from Peugeot, Citroen.

[E-bmw]

K is King said:

Ah the good old PSA 1.6 diesel (DV6) used ubiquitously across many marques.......having had this engine now in a Mini and a Volvo and both suffering from smoking, powerloss etc I can tell you where to go looking......

1. Injector failure / leaking
2. Split in the PCV Valve diaphragm
3. Split in the Turbo Intercooler hose
4. Split in the Turbo Intake pipework (Airbox to Turbo to PCV)
5. Failed Turbo intake seal
6. Failed DPF Pressure sensor
7. Clogged DPF
8. Clogged Fuel Filter

Really good info, thanks for that, in answer to all of your options see below.

1. Injector failure / leaking - I am going to replace injector 3 today as there is a code & (sort of) expected symptoms.
2. Split in the PCV Valve diaphragm - I did check this the other day when I checked the turbo inlet for oil.
3. Split in the Turbo Intercooler hose - Will have a look, but not REALLY expected to be the issue as it is only for the first min or 2.
4. Split in the Turbo Intake pipework - Will have a look, but not REALLY expected to be the issue as it is only for the first min or 2.
5. Failed Turbo intake seal - Will have a look, but not REALLY expected to be the issue as it is only for the first min or 2.
6. Failed DPF Pressure sensor - Did live data test on the soot level/differential also yesterday & all looked good.
7. Clogged DPF - Did live data test on the soot level/differential also yesterday & all looked good.
8. Clogged Fuel Filter - Filter changed at the start of the year.

As above, I will do the injector today & do a re-learn & see how I get on.

[E-bmw]

Well that looks promising.

I have just changed the injector & started the car & there is no start up smoke.

Of course, I now need to do a few injector re-learn runs, but a promising start (lol) after a quick job.

ETA.
Injector learns have now smoothed out the engine running that bit better, so if start up after a day or so laid up is smoke free I am calling it fixed.

Edited by E-bmw on Friday 9th August 14:08

[Krikkit]

Great result, and thanks for posting a solution!