2007 T5 1.6 7H transporter on 160K Smoking during warm up phase

[honest tony]

I an working on this with the intention of making it into a day van. the engine starts and runs fine, but for the first 5 minutes it smokes badly but only on acceleration. on idle its fine and after its warmed up its fine.

I have tested the power to the egr valve and manifold flap and VCDS is only reporting EGR Sensor 2?

I have de -coked the egr valve

so does anyone have any suggestions - luckily I have a 60K mileage 06 van next to it which I can swap parts over to test - today I am swapping the EGR valve!

[Crasher]

What is the VIN and the fault code numbers?

[mickeybo]

engine code would be a very very good start

[honest tony]

Sorry all its a 1.9 my typo,

Engine code? 62kw TDISG5

[honest tony]

is that correct or is BRR useful

[honest tony]

Update- it smokes worse if accelerating hard - and hardly at all if i drive gently, also when accelerating hard i can hear a rasping -

[Crasher]

Yes, BRR. To me that sounds like a boost leak, most often a dislocated boost hose into or out of the intercooler but occasionally a split intercooler, traces of oil around the fittings or on the cooler can be a clue or a pressure test is the easiest way but you need the gear.

[honest tony]

Im pretty sure my intercooler is fairly new, I cant see any evidence of oil or sooty leaks - I do get Manifold Flap intermittent to ground and egr sensor 2 faults.intercooler.jpg

[Crasher]

We would carry out a pressure test of the system using the VW kit and other garages use smoke based systems.