Hi, my 2004 kj crd 2.5 is still smoking quite badly from cold. it produces black smoke in a cloud when i rev it when cold or when i first pull away. it also does this when the engine is warm after its been in slow traffic and then i accelerate up to normal speed.
when i rev the engine whilst warming up it puffs a cloud of black smoke out and then makes a click sound on the over run,
also the fuel consumption varies about 4 mpg on the same run and under the same driving conditions according to the fuel computer.
any ideas would be greatly appreciated, thanks.

I bought mine in March, 2010. It smoked when cold. A new thermostat and GDE tune later the smoke was gone. The following summer it over-heated because of bad fan clutch (which was bad when I bought it). Replaced that and all has been well since.

Members here live from Florida to Canada. Knowing your location would be helpful since ambient air temp affects engine temp. Some guys use a fixed flex fan (Florida). In other parts of US members take fan completely off and experience no ever-heating. I can't go east from my place up a mountain pass two miles without a fully functioning fan in summer.

So, you mileage will vary. Read about thermostats and talk to Keith at GDE are my suggestions. Also, disconnect the MAF sensor and see if the smoke improves. Look at temp gauge. It should be very slightly below the center line when warmed up.

It takes a lot of reading to get to the real solutions this board offers. Good luck.

PS All the above is my experience with a 2.8 liter. Your 2.5 was sold in Europe or Australia. If you're in OZ, by all means hook up with Glend at the Aussia KJ forum. Tony CRD is in Spain and is very knowledgeable about the 2.5.

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'05 Sport CRD 107k miles. NOBODY knows everything.

You will have the fixed-vane turbo that uses a waste-gate....this may be sticking.

Or the EGR valve is possibly stuck open...you would have to remove it to see.

Once you have cleaned the EGR it is best to disable it. On the 2.5 CRD this is easily done by disabling the vacuum solenoid.
This is the black plastic contraption sitting next to the main air filter...has a small paper air filter dangling down from it, two small pipes connected on top and a plug with two wires plug in the side.
Remove the small outer rubber pipe from this solenoid and insert a small self-tapping screw into the plastic housing then replace the pipe over the screw head. This will give you better performance and stop abrasive soot being pumped into the intake manifold.

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2002 Export CRD 2.5 Sport