Hello AlanC, I have just fixed a number of probs on my 2.5 CRD 2002. But I still have exactly the same black smoke problems you describe having. In the 2003 Service manual there is a simple procedure for testing your injectors (section 14-17). Unfortunately, I cannot post the attachment here... filesize limit is way too low. PM me your e-mail and I'll email it to you. Rgds, kkc.

Have you tried the procedure to test your injectors and if so what results did you get?

Just tested it. on number 4 i got a few drops... 7ml maybe. On numbers 1-3 I got about 12-15ml each. Number 1 is closest to timing belt. I did not do the combined test for 100ml or more as the return tube and tee are a bit tight to get to.

So according to the Chrysler serviuce manual, this means that the injectors are ok, although the spray pattern may be sub-optimal. I have also heard that if the variation between any two injectors is >10% there is a problem with one injector either releasing too much fuel into the piston (low leak off) or too little (high leak off).

In summary I have great acceleration, great consumption and a ton of black smoke when hard accelerating...and the exhaust is irritating to the eyes.. i.e. fuel/air mix is rich. As far as I can tell all airways are clear.. changed air filter and fuel filter (which was very dirty - note to self, change fuel filter every year on any diesel...!).

Previously I installed new EGR valve and solenoid, cleaned the EGR out pipe which was badly blocked.

If anyone has any other ideas - I am all ears...!