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Black Smoke - finally fixed!!
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Marknexus
 


Member Since: 15 Nov 2014
Location: Moreton in Marsh
Posts: 112

United Kingdom 2006 Discovery 3 TDV6 HSE Auto Buckingham BlueDiscovery 3
Black Smoke - finally fixed!!

Just thought Id rely this tale of woe in case it helps someone else...

I have had a persistent issue with awful black smoke on anything other than light throttle, and I first asked for help on here over 3 years ago (shockingly!) - and went through all the usual causes hoses, Intercooler etc etc.

After many man hours and much (MUCH!) frustration, I have finally found the issue......

Long story short - when the EGRs were blanked (i bought the car this way) some complete numpty must have deleted the butterfly valve by extracting the entire shaft and then not refitting it!!!

This left a 6mm or so hole in the side of the throttle body, from which most of my boost was escaping causing massive overfueling, horrible flat spots etc.

It was impossible to see this by inspection because the (censored) idiot who did it, refitted the rotary actuator back onto the throttle body, essentially hiding the missing shaft / hole....

I have temporarily plugged the hole and its a totally different car to drive!!

Naturally I am hugely embarrassed that it took so long to find such an obvious issue - so I am risking ridicule in the hope that this might help someone else, on the off chance that this has happened to other vehicles.

(Also, if anyone has a spare shaft and butterfly valve, Im in the market for one!)
 

Last edited by Marknexus on 8th Sep 2018 8:51 pm. Edited 1 time in total 
Post #19817688th Sep 2018 7:14 pm
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john ryan
 


Member Since: 05 Apr 2006
Location: leamington spa
Posts: 121

2005 Discovery 3 TDV6 S Manual Alveston RedDiscovery 3

When I did mine, years ago, the trick was to remove the butterfly, but replace the actuator AND shaft. That way the system continues to think someone is at home, but the holes are plugged I presume you are aiming for that arrangement.
  
Post #19817728th Sep 2018 7:22 pm
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Marknexus
 


Member Since: 15 Nov 2014
Location: Moreton in Marsh
Posts: 112

United Kingdom 2006 Discovery 3 TDV6 HSE Auto Buckingham BlueDiscovery 3

Indeed - the shaft should definitely have been refitted!

Now i have found the problem, I would want to fit the shaft (to stop the air leak) and also the butterfly in order to retain the air cutoff feature.
  
Post #19817828th Sep 2018 7:39 pm
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john ryan
 


Member Since: 05 Apr 2006
Location: leamington spa
Posts: 121

2005 Discovery 3 TDV6 S Manual Alveston RedDiscovery 3

But if you fit the butterfly, and the egrs are blanked, I would think air flow is blocked when the butterfly closes - so what is the advantage you seek? Engine braking? Just curious.
  
Post #19817878th Sep 2018 8:19 pm
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Marknexus
 


Member Since: 15 Nov 2014
Location: Moreton in Marsh
Posts: 112

United Kingdom 2006 Discovery 3 TDV6 HSE Auto Buckingham BlueDiscovery 3

The butterfly allows the ECU to shut off the air supply to the engine. The impact of retaining the butterfly is negligible as it generates minimal air resistance in the intake tract (bearing in mind most of the time the intake is at positive pressure from the turbo)

I dont know if its needed, but it sure feels like a good idea to have the ability to positively stop the engine - in the unlikey case of a runaway etc.

I have seen various opinions on this, and my current assessment is its better to have it. Im sure others may know better and can provide further advice.
  
Post #19818008th Sep 2018 8:47 pm
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Pete K
 


Member Since: 15 Jan 2016
Location: GL
Posts: 10335

England 2005 Discovery 3 TDV6 HSE Auto Rimini RedDiscovery 3

Ask this guy if he wants to sell you the shaft

https://www.disco3.co.uk/forum/no-bongs-go...74742.html


Leaving the butterfly in can cause other difficult to find problems.

When the car tries to get most of the air from the EG, the butterfly closes, and as you have blocked the EGR's you don't get any air from them, therefore the engine is strangled
  
Post #19818178th Sep 2018 10:13 pm
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john ryan
 


Member Since: 05 Apr 2006
Location: leamington spa
Posts: 121

2005 Discovery 3 TDV6 S Manual Alveston RedDiscovery 3

I agree Pete; in any event I have run with blanked egrs and without a butterfly for 9+ years without any adverse effect
  
Post #19818489th Sep 2018 9:02 am
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Marknexus
 


Member Since: 15 Nov 2014
Location: Moreton in Marsh
Posts: 112

United Kingdom 2006 Discovery 3 TDV6 HSE Auto Buckingham BlueDiscovery 3

Thanks Guys - appreciate the input.
  
Post #19819769th Sep 2018 5:17 pm
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