MAN TGX 480 (2008) 6x4 EURO4 - Black Smoke & Power Loss: Turbo, Injectors, Exhaust Issues

Hello .
I have a Man TGX tractor unit 6x4 EURO4 480 KM 2008.
The problem is black smoke and lack of full power, when adding gas at a standstill, there is also a black cloud of smoke, which should not happen in E4.

I will also add that the car once clogged the catalyst with soot so that it had to be flushed because the pressure in the exhaust system was increasing.

The injectors were checked in the car (printouts attached), the air cooler (there was a small leak), turbo (minimal play), the boost sensor was replaced with a new original one, the entire exhaust gas recirculation was replaced and I also tried to plug it, but without changes.

Turbo parameters are in the norm tz. the turbine in higher gears beats 2.9-3.1 BAR
after that no errors on the computer.

I am asking for any suggestions, what else can be checked or what parameters to look at?

Personally, my feelings are towards the turbine, but I would not like to replace parts for PLN 3,000 blindly, so I am looking for advice on how to check it.

I would bet on a turbine or an air filter. Are there any errors? Black smoke usually means too high a fuel to air ratio. How did you check the injectors? Because the best method of checking them is "on transfers", i.e. manually.

The injectors were checked for overflows and tips, if the injection was too much fuel or poured, the overflow would not detect it.

Hello. And is the engine brake working properly? It is appropriate to check the exhaust gas flap of the engine brake because if it is damaged, it may limit the flow of exhaust gases. When were the valves adjusted? (What do the camshaft lobes look like?) What are the injection corrections for the individual cylinders? What is the value of the fuel rail pressure with the engine stopped? Engine temperature sensor checked? You could also be tempted to check the compression pressure if the previous questions did not reveal the cause of the failure.

The brake was checked when disassembling the turbo, the valves were adjusted, corrections hmm, I got information that after the corrections, nothing seems to be clear that only a physical check of the injectors gives something, which is shown in the appendix regarding sensors and fuel pressure, it was not checked, but whether the fuel pressure will play roles in a black hole?
As for the compression, it has not been checked, it is difficult to check in this engine without proper facilities: /
As for the temperature and pressure sensors, I will check it.

What color is this smoke evidently black as in the tdi pass or rather gray black?
Because if you have everything checked, do the compression test - you can do man cats.
The Turbo has been checked - from the entrance and exit sides, plus not only the hatch on the mountain that it moves, but does it not lock in the closed position?
Do you have control of the Evb valve (mountain or there) in this engine? Are there any bugs after your repairs, e.g. ffr?
There is always backlash on the turbine - it is compensated by oil - of course possible
(play) to be compensated.

Procedure when "vehicle smokes black"
Basically it is necessary to determine in what operating condition black smoke is present:
- Does the engine always smoke?
- Do they only smoke when accelerating?
So far, the following possible causes have been identified:
- Installation error, injector strained
- Leakage between the combustion chamber and the drainage pipe, lower injector seal
(CU O-ring) leaking
- Injector wear (large amounts of leaks)
- Incorrect projection of the nozzles
If black smoke was found during the test drive, we recommend the following
procedure:
- Read error memory EDC7
- If errors are stored, analyze them according to the troubleshooting guide and repeat the ride
trial.
If the vehicle continues to smoke black and the fault memory is empty:
- Experience has shown that in low-mileage engines, black smoke can be induced by
injectors mounted under tension
Remedy: Loosen all pressure pipe and injector fasteners then carefully
tighten. If this does not work as expected, it causes smoke when accelerating
the injectors may be worn.
Therefore, carry out the individual measurements and replace the corresponding injector.
- If the turbocharger is damaged earlier, oil may also be forced into the exhaust silencer.
It can also cause black smoke when accelerating.
Solution: Replace exhalation.
If there is still black smoke:
- Carry out the RPM increase test at least twice
If the RPM increase test is successful:
- Remove all injectors and
- check the seal in the nozzle area (CU ring seal) for dryness
- Check the diameters of the CU ring seals
If one or more injectors are found to be leaking and / or o-rings
CUs are too large in diameter:
- Replace the O-rings and pressure pipe stubs and reassemble them correctly
injectors
- Carry out a road test Procedure when "vehicle smokes black"
Basically it is necessary to determine in what operating condition black smoke is present:
- Does the engine always smoke?
- Do they only smoke when accelerating?
So far, the following possible causes have been identified:
- Installation error, injector strained
- Leakage between the combustion chamber and the drainage pipe, lower injector seal
(CU O-ring) leaking
- Injector wear (large amounts of leaks)
- Incorrect projection of the nozzles
If black smoke was found during the test drive, we recommend the following
procedure:
- Read error memory EDC7
- If errors are stored, analyze them according to the troubleshooting guide and repeat the ride
trial.
If the vehicle continues to smoke black and the fault memory is empty:
- Experience has shown that in low-mileage engines, black smoke can be induced by
injectors mounted under tension
Remedy: Loosen all pressure pipe and injector fasteners then carefully
tighten. If this does not work as expected, it causes smoke when accelerating
the injectors may be worn.
Therefore, carry out the individual measurements and replace the corresponding injector.
- If the turbocharger is damaged earlier, oil may also be forced into the exhaust silencer.
It can also cause black smoke when accelerating.
Solution: Replace exhalation.
If there is still black smoke:
- Carry out the RPM increase test at least twice
If the RPM increase test is successful:
- Remove all injectors and
- check the seal in the nozzle area (CU ring seal) for dryness
- Check the diameters of the CU ring seals
If one or more injectors are found to be leaking and / or o-rings
CUs are too large in diameter:
- Replace the O-rings and pressure pipe stubs and reassemble them correctly
injectors
- Carry out a road test Procedure when "vehicle smokes black"
Basically it is necessary to determine in what operating condition black smoke is present:
- Does the engine always smoke?
- Do they only smoke when accelerating?
So far, the following possible causes have been identified:
- Installation error, injector strained
- Leakage between the combustion chamber and the drainage pipe, lower injector seal
(CU O-ring) leaking
- Injector wear (large amounts of leaks)
- Incorrect projection of the nozzles
If black smoke was found during the test drive, we recommend the following
procedure:
- Read error memory EDC7
- If errors are stored, analyze them according to the troubleshooting guide and repeat the ride
trial.
If the vehicle continues to smoke black and the fault memory is empty:
- Experience has shown that in low-mileage engines, black smoke can be induced by
injectors mounted under tension
Remedy: Loosen all pressure pipe and injector fasteners then carefully
tighten. If this does not work as expected, it causes smoke when accelerating
the injectors may be worn.
Therefore, carry out the individual measurements and replace the corresponding injector.
- If the turbocharger is damaged earlier, oil may also be forced into the exhaust silencer.
It can also cause black smoke when accelerating.
Solution: Replace exhalation.
If there is still black smoke:
- Carry out the RPM increase test at least twice
If the RPM increase test is successful:
- Remove all injectors and
- check the seal in the nozzle area (CU ring seal) for dryness
- Check the diameters of the CU ring seals
If one or more injectors are found to be leaking and / or o-rings
CUs are too large in diameter:
- Replace the O-rings and pressure pipe stubs and reassemble them correctly
injectors
- Carry out a road test Procedure when "vehicle smokes black"
Basically it is necessary to determine in what operating condition black smoke is present:
- Does the engine always smoke?
- Do they only smoke when accelerating?
So far, the following possible causes have been identified:
- Installation error, injector strained
- Leakage between the combustion chamber and the drainage pipe, lower injector seal
(CU O-ring) leaking
- Injector wear (large amounts of leaks)
- Incorrect projection of the nozzles
If black smoke was found during the test drive, we recommend the following
procedure:
- Read error memory EDC7
- If errors are stored, analyze them according to the troubleshooting guide and repeat the ride
trial.
If the vehicle continues to smoke black and the fault memory is empty:
- Experience has shown that in low-mileage engines, black smoke can be induced by
injectors mounted under tension
Remedy: Loosen all pressure pipe and injector fasteners then carefully
tighten. If this does not work as expected, it causes smoke when accelerating
the injectors may be worn.
Therefore, carry out the individual measurements and replace the corresponding injector.
- If the turbocharger is damaged earlier, oil may also be forced into the exhaust silencer.
It can also cause black smoke when accelerating.
Solution: Replace exhalation.
If there is still black smoke:
- Carry out the RPM increase test at least twice
If the RPM increase test is successful:
- Remove all injectors and
- check the seal in the nozzle area (CU ring seal) for dryness
- Check the diameters of the CU ring seals
If one or more injectors are found to be leaking and / or o-rings
CUs are too large in diameter:
- Replace the O-rings and pressure pipe stubs and reassemble them correctly
injectors
- Carry out a road test

It's nice that someone wrote such a long argument, only in my opinion a few things are there for someone who supports, for example, Mana in this case, - as a help and reminder what to pay attention to, because the content .....
We know that a colleague entrusts this repair to someone.
For example, loosen the pipes connecting the injector and tighten it gently! There is a special procedure for this with the values of using the dynomometric key - it applies only in the event of error 3779.
Oring on injection, seal to be checked? If the dumplings were checked plus no edc bugs.
Why take them out - after all, my friend does not write anything about dark diesel in the tank or filter - the exhaust gases mix.

Sorry, something typed again for me. I think that there is never too much information. I would try to replace the catalyst.

First disconnect the engine flap and lock it in the open position, then give it a brush without saving fuel, i.e. driving above 1500rpm to almost max, just to blow soot out of the exhaust and burn it well. Then driving with a computer and observation of parameters, required and actual manifold pressure, rail pressure dim. and real. If they almost match, check the lift of the shaft cams, if ok, the injectors should be replaced. E4 has the right to let go of a little black farther when shifting to a higher gear or stepping the gas on the floor.

Added after 1 [minutes]:

Attachment not readable.

As for the mountain flap, it is stiff and does not block the exhaust.
But I'm beginning to suspect what might be happening.

We recently had injections on the E5 TGX 540 from AB, before the repair, the car did not kick.
Now, when the injectors have been regenerated, I got information from the driver that you can see that a bit of smoke is not as much as the E4, but it is smoking.

Sea injections are made wrong (doses) because they were done in two separate people.

Hello,

I am writing this post because I have mana tgx 18.400 2012. Mileage equal to 500,000. Suddenly, overnight, it began to smoke terribly black when accelerating and a total lack of power ..

I connected texe and unfortunately there are no errors. Adblue works.

I took photos of injectors correction on a hot engine.

Here at load.



Here at idle.


Can someone tell me which injectors to replace?

best regards

At least 2, i.e. 1 and 6

I believe that if the injections would fail or the pump or ...
This, unfortunately, would be a minimum error of 3779.
Just somewhere with a mileage of over 500,000 km, they may be weaker, but also how much is worked at stationary speed at a standstill, what fuel, etc.
Corrections are one thing, but the overflow test must also be carried out, i.e. the latter.
If you wrote after 30 seconds or a minute, I had xx ml. - I wrote that, I would replace the injectors without this attempt, I would not risk in my car.
Black smoke is injection? Fuel? Is there a problem with the air intake side?
Unfasten the elbow behind the turbine and see if there is anything else there, i.e. the blades on the turbine?
best regards

Everything was solved. The mountain brake is stuck in the closed position. Done and the car runs back and does not smoke.

best regards