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Old 18-03-2017   #1
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500 Diesel smokes with clanging

Hi all, I have an 09 Fiat 500 turbo diesel manual tans. I bought it with issues, believed to be blocked DPF. The previous owner had replaced the fuel pump, the glow plugs and the injectors chasing a problem, and bailed out when it still gave trouble.

I removed the DPF and flushed it until high pressure water came out clean. I also removed the turbo and checked it-no movement in the shaft and no oil stains, and hardly any oil in the intercooler. I reassembled the car and ran it. perfect idle and no issues until it got to operating temperature and put under load.

A knocking (almost like a failed big end) noise came from the engine bay, maybe 6 or so knocks / clanks, then white smoke came pouring out of the tail pipe. No smoke in the engine bay, just out the pipe. I drove it back home smoking like James Bonds smoke screen car- no knocking just smoke.

I left it for a day, and tried again. Car drove perfectly for about a mile, no smoke, then some more knocking and smoke again, also felt like the engine was down on power - feeling like a miss.

Day 3 I sprayed a can of EGR cleaner into the air inge and went off for a drive. Went 10 miles at 3000-3500 RPM and all good. got a few little spurts of rattle and puff of smoke when it made noise but backing off stopped the noise and smoke. Loading up the car then made the noise come on faster, and the smoke quite profuse, I really had to limp it home to avoid the rattle and smoke.

Any ideas as to what this knocking / clanging is? When it happens then the smoke comes, I get the feeling its a solonoid or valve that opens and shuts and gets stuck causing the smoke. Could this be EGR? All help greatly appreciated
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Old 18-03-2017   #2
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Re: 500 Diesel smokes with clanging

Get a compression test done? head gasket?
no idea what the noise is can you replicate it whilst stationary?
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Old 19-03-2017   #3
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Re: 500 Diesel smokes with clanging

Yes, a compression test is a good idea. Do it when the engine is giving problems.

Compression testing on a diesel isn't so easy of course. Dunno if you can the tester connected to the glow pug holes, but other than that, you'll need to remove the injectors.

Good luck,
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Old 19-03-2017   #4
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Re: 500 Diesel smokes with clanging

OK so the smoke is actually light grey not white. noise sounding like an engine bearing but it is not there at idle. I have a scan tool coming so I can note the log then clear the fault code list, then retest.
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Old 19-03-2017   #5
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Re: 500 Diesel smokes with clanging

Quote Originally Posted by gtv6capri View Post
OK so the smoke is actually light grey not white.
I'm thinking of a stuck or broken valve or something, not the head gasket.

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Old 19-03-2017   #6
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Re: 500 Diesel smokes with clanging

When my 08 mjet does a dpf regen there's a fair amount of white/grey smoke out the back. The engine note also changes slightly. I can only describe it as a slightly more metallic ring sound. If the car has recently done a regen and i stop and turn the car off sometimes​ there's a rattle from underneath.

Maybe your car is constantly trying to force a dpf regen?
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Old 19-03-2017   #7
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Re: 500 Diesel smokes with clanging

How does the cooling liquid looks just after the issue occurred (bubbles or loss of liquid)? Grey smoke might be cooling liquid / head gasket issue.
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Old 20-03-2017   #8
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Re: 500 Diesel smokes with clanging

I had put a bottle of DPF cleaner in the tank, it is still in there. The battery has now decided to quit so Ill have to get another one and await my scan tool arrival to investigate further
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Old 20-03-2017   #9
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Quote Originally Posted by gtv6capri View Post
I had put a bottle of DPF cleaner in the tank, it is still in there. The battery has now decided to quit so Ill have to get another one and await my scan tool arrival to investigate further
Try the Batterymegastore online very good but check the physical size vs your tray.
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Last edited by John202020; 20-03-2017 at 09:02.
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Old 20-03-2017   #10
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Re: 500 Diesel smokes with clanging

No 1 injector is the one that does the DPF regen.

If its faulty, then you will get the knocking and smoke symptoms.

D
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