Excessive smoke on new-gen engines injector calibration or EGR blockage

[Alan]

Are you noticing excessive smoke when you start up your new-gen engine? It could be a calibration issue with the injectors, or maybe that EGR is blocked again.

Share some troubleshooting tips and tricks.

 

[SacRed]

Last winter, I had quite the experience. When starting up in the cold, it was like a fog machine going off until things heated up. It turned out that the injector calibration was just slightly off, leading to overfuelling at startup. A reflash and a thorough cleaning of the EGR sorted it out completely.

 

[redm4chineguy]

Lately, I’ve been trying to get to the bottom of a different issue. My engine would smoke heavily after sitting for a few days. The injectors tested fine, but a software update fixed the timing for cold starts. It’s really impressive how one small calibration adjustment can make the engine feel like brand new.

 

[Rustinpeace]

I've come across similar issues a few times. A new engine with low hours can still puff out a huge cloud of smoke on startup.
For me, it was a sticky EGR valve causing poor airflow.
I took it out, cleaned it up, and since then, the starts have been a lot cleaner.