2003 Citroen Relay 2.2 HDi - Bizarre Heavy Smoker

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Sun 23 Jun 2019 11:31
2003 Citroen Relay 2.2 HDi - Bizarre Heavy Smoker - Citroen Surf Bus

Has ANYONE ever seen these symptoms before? Done many searches but apparently not!

Engine always starts perfectly.

After 30 secs at idle though, starts smoking and losing power.

Driving away under load (esp. uphill) prevents/ clears it in seconds.

Had this quirk for years now, but yesterday ... very heavy smoke and power loss. Left to stand few minutes then pulled away and cleared it by driving hard.

Today ... Will only drive for 20 secs before huge clouds of grey/ black smoke appear.

Tried blanking EGR, but no effect.

Any sensor fail or other cause might be responsible, boffins? I'm stumped! ( :

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Sun 23 Jun 2019 18:41
2003 Citroen Relay 2.2 HDi - Bizarre Heavy Smoker - elekie&a/c doctor
Is this running a Ford Transit engine?
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Sun 23 Jun 2019 23:44
2003 Citroen Relay 2.2 HDi - Bizarre Heavy Smoker - Citroen Surf Bus

Hello mate, thanks for replying ( :

It has the Citroen HDi, not the Transit engine. Although I guess that my symptoms might apply to many modern diesels?

Any ideas?

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Mon 24 Jun 2019 00:10
2003 Citroen Relay 2.2 HDi - Bizarre Heavy Smoker - trebor1
Possibly a Injector failure. I had the same on my relay, was terminal in the end as blew a hole through top of piston, garage told me injector problems are common ( have to be programmed to ecu so main dealer job and expensive )
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Mon 24 Jun 2019 07:26
2003 Citroen Relay 2.2 HDi - Bizarre Heavy Smoker - madf

There will be a valve on the engine designed to cent oil smoke into the intake manifold usually a PCV valve. These block and give symptoms described as air pressure builds up in engine and goes past the piston rings carrying oil with it...

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Mon 24 Jun 2019 17:47
2003 Citroen Relay 2.2 HDi - Bizarre Heavy Smoker - Citroen Surf Bus

Case solved, folks!

The butterfly valve on the inlet manifold (what is it for? Cold starts?) was being held shut by the solenoid valve. Disconnected it and bingo!

The long term problem of smoke shortly after starting, clearing when warmed is still there - but the horrendous grey and black heavy smoke/ total power loss has definitely gone.

Thanks to all responders who helped me work through the prob. ( :

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Mon 24 Jun 2019 19:08
2003 Citroen Relay 2.2 HDi - Bizarre Heavy Smoker - elekie&a/c doctor
The butterfly valve is also known as an anti shudder flap . It is supposed to open when engine is running and close when engine switches off. It is to stop run on after ignition off. Commonly used on many makes especially Vag models.
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