CDTI air to fuel ratio imbalance

Still trying to figure out why my car smokes so badly that it failed its smoke test.



No synergy fitted.

New inter-cooler O rings.

New PCV.

Turbo checked and fine.

Boost hoses checked.

Wastegate actuator and flap checked.

Injectors swapped one by one with a used injector not ideal but no difference noted at all. (short of at least two being very bad)

Inter-cooler cleaned out and inlet manifold cleaned out as much as possible.

EGR cleaned and blanked temporarily to test no difference.

Remapped but ECU IPK and EWS swapped for a standard 116 tune set by Terry and a bit better but not right, still smoking too much.



The problem initially started with the inter-cooler elbow popping off under hard acceleration, this did cause it to smoke badly and loss of power as expected. I still don't know why this kept blowing apart as surely it should not do that?



It was after that it steadily seemed to get worse.



It has the original exhaust on the front section and a replacement rear silencer. So the cat is around 10 years old now.



My thought it that there is plenty of fuel being injected but not enough air to combust it efficiently causing the black smoke.



My next plan is to hopefully try borrowing a friends ZT which we know runs well and swap his injectors into mine to rule my injectors in or out (he doesn't know yet but will be asking him when the weather is a bit warmer).



If that checks out as fine then the exhaust is the only part that could be suffocating the engine maybe due to a collapsed cat causing the air to fuel imbalance.



I really would like to figure this out.

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