Hi all @ FF, My car is a 2004 Stilo 1.6 16v Active Sport - with 42k
As the heading suggests I am experiencing more than normal exhaust fumes coming from the exhaust (the smoke appears to be grey in colour) this tends to subside once I am on the move and the engine has warmed up (it warms up as usual and the temp needle stays bang on centre).
I removed my battery two weeks ago to charge overnight (could this have affected any ecu/sensor settings) and only noticed the smoking the morning after on start up in the freezing cold - It was really excessive . I have had to top up my expansion bottle on a few occasions recently so thought I may be experiencig CHG problems due to loss of coolant. I changed the oil and filter again yesterday to satisfy my curiosity (I only last changed it 4 months/1500 miles ago) the oil showed no signs of water/emulsification etc and there in no nasty gunge in the expansion bottle - just clean pink coolant. The car starts first turn of the key every time and runs like a dream and returns me 40+ mpg. There are NO faults showing at all on the dash.
Something just doesn't seem right on start up - even the wife said it was getting smokey out there when I started up and she knows zilch about cars !!
Is it the start of CHG problems or have I perhaps blown a valve seal ?? Any advice or comments would be most welcome - Thanks alsimmo

tricky. I would, if you can, remove each spark plug and inspect. if they are burnt or old looking, replace. If they have oil on them, thats probably your issue. As you seem to be loosing coolant, I am even more suspicious of a little leak somewhere ALTHOUGH the loss off coolant could just be an air trap in the system somewhere that needs to be cleared.

I suppose with it being so cold recently, that will certainly make smoke appear worse (hot gasses hit cold air = smoke, its just condensation), maybe its made worse by your CAT in the exhaust system-too much moisture inside etc. As it clears after warm up, im inclined at this stage NOT to worry too much about HG failure, but id be keeping an eye on the coolant almost daily, just to be sure, and try to ensure the system is fully purged of air (radiator and heater matrix).

In the past, i had two old V6 Mazdas, nice little sports cars. Both gave smoke in the cold same as yours, nothing excessive mind, but still, it was there. Had that for over 4 years without issue, so try not to worry too much until you have checked a few more things over, good luck chap!

Thanks for your comments Clivvy - very much appreciated. Forgot to say that I also checked the spark plugs and they were fine (only changed at last service 4 months/1500 miles ago). I also cleaned the MAP sensor with electrical contact cleaner and cleaned the inside of the throttle body. I will see if I can find any airlocks etc in the cooling system. Regards alsimmo

alsimmo said:

Thanks for your comments Clivvy - very much appreciated. Forgot to say that I also checked the spark plugs and they were fine (only changed at last service 4 months/1500 miles ago). I also cleaned the MAP sensor with electrical contact cleaner and cleaned the inside of the throttle body. I will see if I can find any airlocks etc in the cooling system. Regards alsimmo

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ah ok, thats a few things knocked off your list then, a good sign if the sparks are dry. Have you checked/cleaned the MAf? Might also be worth popping in some injector cleaners or system cleaner and taking it for a hot blast, that might help (might not!)..

Hi Clivvy, Am I right in thinking I dont have a MAF sensor ?? May consider the injector cleaning option if all else fails. Thanks again alsimmo

Hi. Just a thought, have you changed to a differentmake/grade of oil when you did the services?

Hi Cris, I think I did ! In the summer a put Castrol Edge 0w-30 in it. I changed it to Magnetec 10w-40 yesterday. Could this be where my problem has come from ?? Regards alsimmo

MAF sensor is only for the Abarth and JTD versions mate, I have the 1.2 and it makes a bit of smoke when it's started - a few blasts with the throttle and it settles What is the smoke like when the engine idle speed drops to normal speed after its initial warm-up? When the idle revs drop down to normal the smoke pretty much dissappears on mine. If you are starting it up and driving it straight away then you'll never know, let it run and drop the idle down and see if the condition changes.

-Mark

MarkThompson4 said:

MAF sensor is only for the Abarth and JTD versions mate, I have the 1.2 and it makes a bit of smoke when it's started - a few blasts with the throttle and it settles What is the smoke like when the engine idle speed drops to normal speed after its initial warm-up? When the idle revs drop down to normal the smoke pretty much dissappears on mine. If you are starting it up and driving it straight away then you'll never know, let it run and drop the idle down and see if the condition changes.

-Mark

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Hi Mark, Thanks for your comments. It appears to settle down somewhat once it reaches normal running temp. It still appears to be a little more smokey than I initially thought it was - Maybe it appears worse with the colder conditions ? Also a little worried at losing coolant from the expansion bottle - Having to keep on top of it every couple of days ! Regards alsimmo

It is most likely to be the colder conditions, take it it wasn't like this in the "warmer" summer months?

Check for a few days how much coolant you are losing, check for coolant on the ground when the car's been parked overnight. Check all the coolant hoses are securely fitted with the circlips in place.

I recently had to change a rubber seal that fits round a metal pipe that fits into the water pump housing on my 1.2 - had a leak coming from above the oil filter which is where that seal is situated. New one fitted and now no more coolant leaking onto the oil filter!

Just going to check eper to see if you have anything similar...

But you really shouldn't worry about a HG issue, unless the coolant loss gets really bad then perhaps get a compression test should be carried out on your Stilo.

-Mark

Here you go alsimmo, the part numbered "2" in the picture is similar to what I had to replace, but have a general look around the cooling system to check for other possible areas where coolant may be leaking. If there are no visible signs of leaks then as mentioned before you should try bleeding the cooling system.

*Update* - Excessive smoke from exhaust on cold start turned out to be CHG Failure !

Hi all @ FF,
I would just like to report back on my recent exhaust problem. Upon further investigation my excessive smoke from the exhaust turned out to be steam It turned out to be Ye Olde CHG faiure !
I purchased a Full CHG Set, Head Bolts and a Water Pump from Shop4Parts for a very reasonable £127 including their online discounts, the extra 10% FF Members discount and Next Day Delivery
Cylinder Head has been skimmed and replaced and the job is now complete and running fine as of yesterday (Not bad seeing it was Christmas week and beer had to be consumed inbetween sessions ). I assisted my mechanic friend who works at a local independant garage. He Informed me the job was booked @ 10.9 hours at his establishment.
Thanks for all input received with my problem. I would like to take this chance to wish all FF members and guests a very Happy problem free New Year
Regards alsimmo

Re: *Update* - Excessive smoke from exhaust on cold start turned out to be CHG Failu

Glad it's working for you again, hope your mechanic knew what he was doing when refitting the timing belt!

My 1.2's hit 130k, still runs sweet as a nut, but I should probably look at replacing the gaskets soon - will look at shop4parts when time is right they seem very reasonable

-Mark

Hi Mark,
The guy that has done the CHG for me changed the cam belt for me last year when I bought the car so I had confidence in him. He has access to the correct locking tools etc via work so was no difficulties as he knew what to look out for with this tricky procedure. Thanks again for your interest and all the best for the New Year Mark.
Regards alsimmo

ps. I can highly recommended Shop4Parts. Mick was very helpful with my purchase will definately use again even if not the cheapest they were excellent quality parts and received within 24 hours so you can shop with confidence !