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Message: <blockquote data-quote="r37720" data-source="post: 10720" data-attributes="member: 906"><p>Forummers, Here the storyboard how it was finally fixed. 1. Early April - when I pressed down to full throttle, the black smoke is heavily noticeable. 2. May - I sent my car to AB SC for regular service and mentioned this issue to them, they told me the problem is suspected due to breather valve stucked - amost commonly issue to diesel engine. 3. June - Get advise from Lee Motor SC. They suspected due to both breather valve and high pressure pump failed to give to correct specification. 4. Sept - I changed both breather valve and HP pump and drive for long distance from Kulim to malacca - the problem still there: the black smoke still very noticeable. I can feel the bikers can get sore throat sucking my black smoke. My bumper and rear bonnet is heavily deposited with black smoke. I was so dammed pissed off that I need to clean those stuff every time I went for long distance. Not to mention that the exhaust pipe has a lot of dirty sludge and need to do frequent cleaning. 5. Oct - Complaint again at AB about this issue not yet solved. They hook up the OBD and they said the AFM is at higher spec but not yet failed. They adviced me to change this. I however refused to change cause it cost me another RM2K+. 6. Nov - I sent my car to one of outside mechanics that used to maintain my previous E46. He dismantled the throttle body and and the inlet manifold. Very suprising he found out that the throttle inlet pipe almost blocked with the sludge and the inlet manifold is heavily deposited with the diesel by-product. He cleaned it up for almost 2 days using special chemical. Once all this done, the black smoke was minimised significantly. The mechanic told me after 2 days it should be gone due to left over inside the combustion chamber which cannot be removed. However after two days there was still sign of minimum black smoke and he couldnt do anything about it. 7. Nov end - Since I am so tired with the dirty tail pipe then I changed the exhaust pipe that are facing downward so that all the smoke flows down to the ground and nobody cant see how dirty is the tailpipe 8. Early Dec - Never satisfied with the black smoke, I sent again to AB for sofware upgrade and reset all DDE to factory setting. Well... not much improvement. 9. End Dec - Two days ago I decided to try my luck by fixing it myself. Note that I have some experiences in fixing the car during my student time. a. I dismantled again the breather valve, cleaned it up and checked the valve is still in good working condition. b. I dismantled the air filter. Suprisingly, I found the air filter is not mounted properly. Tthe mounted rubber is not mount nicely into the mounter until the rubber is torn out and covered almost 40% of the air inlet to the AFM (Air mass flow meter). This is workmanship issue of SC staff. c. I dismantled the throttle body and inlet manifold. The throttle body is so dirty until you hardly see the metal surface. There is metal shaft/rod that I think is meant to control the air flow seems already stucked. I used the brake cleaner chemical to remove this and after that I soaked into WD40? to ensure to shaft can be freely moved. d. I cleaned the inlet manifold until all the sludge is removed. It took me about 6 hours to clean this up. After putting back all the stuff and at first engine cranking the car start and the most suprising thing is not black smoke at all. NO BLACK SMOKE ..... I have beend driving for 2 days and every time when I parked the car, I will rammed the engine and asked my wife or kinds to check and really no smoke at all. Conclusion : The air filter mounting rubber blocked the aFM to cause not enough air to go in. After many months, due to fuel riched ratio (inefficient burning) the sludge deposited around throttle body and inlet manifold to cause the rod stucked and failed to further control the air intake.  Hope this will be a guidance to any of the diesel owners.</p></blockquote><p></p>

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