OK folks, thanks for joining my crowdsourced troubleshooting session I'll just bash through some suggestions here and then finish up with a to do list, see if it makes sense.
@craigxxl- I was hoping you'd post! The dirty oil/whatever came from the EGR pipe not the intercooler pipe. It doesn't seem like oil/water mix, too consistent- I've left it to see if it'll settle or separate or anything like that.
I need to check the intercooler tomorrow so I'll follow your drain suggestion- I think I'm on the line of eliminating that rather than confirming it but good to have such a clear line, cheers!
I'm going to put one scottish pound on it being smoke not steam, partly just because it moves heavily if you know what I mean, but mostly because of the smell.
@Inbred- pressure sensor seems reasonable, it ought to code but I don't like assuming that it will. I'll shelve that for the moment as I can't test it myself (it's like House MD this "Don't test for that" "Why not?" "Because if it's that, he's dead"). It's not temperature sensitive and does start fine from cold so I'm inclined to rule out glows.
@bikebuoy- my thinking is not head gasket- engine oil is nice and oily, no emulsion, and both oil and coolant levels seem stable (it could be burning a little oil or leaking a little water but not in quantities) It is on the list of things to think about later though.
@Suggsey- I've run it for a good time on the drive and it doesn't seem to be dropping anything, will see what I can get with a bit of paper. Holes in pipes definitely a contender but again, a bollocks to test for. But definitely on the list.
It is remapped and decatted, has a pipercross filter on it (in standard airbox, I'm not a chav!) and normally EGR bypassed but otherwise completely standard. I cleaned the air filter on general principles, tbh it'd have to be in terrible condition to cause this (when I bought the car, the old filter was incredibly filthy, also there was a screwdriver in the airbox, neither caused obvious problems)
@olly and inbred- aside, the EGR bypass does trigger a low airflow fault which every so often fires a dashboard warning light, even on the euro3. A little hole in the plate cures that but I kept the solid plate and just reset the code from time to time- I like plugging in the laptop and watching the live feeds anyway, that's some fast and furious shit. NOSSSSSSS!
Ahem. Moving on!
@mc- cheers for the offer! It feels like a solo job right up til I get the pros in but I may end up taking you up.
I was wondering about shuffling a single new injector around, injector is definitely top of my list... I can code a new one no bother and it should be fairly easy to swap... though TBH getting them all checked might not be a bad idea on general principles so I'm swithering about that.
I didn't know that about the EGR raising piston temps. The engine temperatures are normal but then that doesn't neccesarily connect, interesting. (why is that? Presumably the EGR increases the amount of oxygen?)
Repeat removal of EGR pipe, see if same results
Try to drain intercooler
Decide what to do about injectors but lead option- get one good one, shuffle em.
Put off thinking about holes in pipes and pressure sensors!
Should probably change the fuel filter, it's not the cause here but I don't know how old it is.