What are your temperatures there?
Attach a video of the supposed heavy smoke and fuel scent on startup. Obviously it's going to smell like fuel, you don't have a missions filtering that out anymore.

Where did you buy the injector from, is it OEM, and how much was it?

 

Temps are dipping down into the 40's but it was doing this last month in the 70's and 80's as well, not as bad but that is likely condensation mixing in.
I'll try and grab a video tomorrow of the smoke on start.
Injector was purchased from FCPEuro, I believe it is a new part but I think the box said reman somewhere on it. Audi VW Fuel Injector - Bosch 059130277AM
Vehicle has 133k miles, tuned and deleted for about 1000 miles now.

Edit: Confirmed the injector is a reman but the listing says it is from Bosch.

 

Just to verify, #6 is the rear most cylinder on the driver side(North America)?

 

If you're asking that, how do you know you "replaced" the injector that you think you replaced?

 

I'd compression test that cylinder. Could be stuck/carboned up rings. Once warmed up they seal better.
That blowby isn't bad but a bit more than normal.

With a cat delete your definitely going to notice way more smell. If it burns your eyes out after a couple of seconds there could be other issues.

 

I'd compression test that cylinder. Could be stuck/carboned up rings. Once warmed up they seal better.
That blowby isn't bad but a bit more than normal.

With a cat delete your definitely going to notice way more smell. If it burns your eyes out after a couple of seconds there could be other issues.

It's not eye burning bad thankfully. It did throw a check engine light this morning which it hasn't done yet so I've got a direction to go in hopefully.

 

I'm with @Dannyboy485
Compression test Cyl 6 as the issue is only on that cylinder.

 

Injector 6 is the injector on driver's side, firewall.

 

The point I was trying to convey was that if you thought you replaced injector #6 but readingss didn't change after the new injector on VCDS injector #6, you probably didn't replace injector #6.

 

Well I replaced the injector nearest the firewall on the North American driver side of the engine.

 

I said in the video a few hundred yards, I meant a few hundred feet, it stops smoking by the time im out of the parking lot. It will start smoking again on the next cold start.

 

Wow that's interesting. It sure looks like oil. Is that definitely diesel fumes or is it oil?

 

It's diesel, oil level either doesn't change or goes up slightly which is what part of what lead me to thinking it was a leaky injector.

 

Compression test as per above suggestions. You have a hurt cylinder (that's why the injector deviation remains unchanged even after the new injector.... and why you have so much blow by)..... how much oil are you using? Pull the GP out of #6 and have a look at it.... I bet it's all fowled up.

 

Not consuming any oil though, or it's replacing it with diesel as fast as its consuming it.

 

We were responding at the same time... if your oil level is increasing, it's filling up with diesel faster than it's burning the oil.... diesel is "thinner" so it will wash down the cylinder wall and make it past the rings easier than the "thicker" oil will blow by into the combustion chamber.

 

Ya if your oil level is changing it you've got something bad happening. I'd stop running that engine stat

 

Pulled the intake today to do the compression test and inspect, caked in soot but not "plugged". Cylinder 4 ports were definitely damp compared to the rest which Im not sure I understand as I deleted the egr so im not sure where that moisture could be coming from.

Compression test results:
Bank 1 (passenger side)
Cylinder 1 - 200
Cylinder 2 - 400
Cylinder 3 - 380
Bank 2 (driver side)
Cylinder 4 - 350
Cylinder 5 - 380
Cylinder 6 - 380

 

Are you 100% cylinder 1 is 200? That's way below spec

 

I ran the test twice, unless my gauge wasnt sealing well with that cylinder im pretty sure.

 

Was that on a warm engine?

 

Not fully warm, took me probably 2 hours to get everything pulled off between working on it and dinner.

 

Oil temp needs to be 80deg C for check.

 

I'll go light a fire under it to keep it at temp when I recheck it, or let insurance take it

 

You only have one hurt cylinder.... since 5 cyl diesels were a thing, you should still be good... plus, you're tuned... so it should be a "wash".

 

It's funny you should mention five cylinders, I have a 1963 Unimog 404 with an om617 swapped in.

 

Pretty sure insurance won't cover maintenance neglect 🤔

 

Next job is pulling injector one and check the sealing ring, if it's leaking it may explain both the low compression and the blow by, if not I can still stick a borescope down the hole and check the cylinder walls.

Will of course be cleaning the intakes before reassembly, I've been searching for how best to clean the intake ports and have heard everything from picking everything loose and vacuuming and brushing with acetone to walnut blasting it but that seems a little more risky.

 

Alright, pulled and inspected injector 1, sealing washer and o ring were both in good shape and clearly not leaking. I was able to stick a borescope down the injector hole, the piston was in good shape and I didn't see any pitting or wear on the cylinder walls. After cleaning the intake plenum, runners, and ports I re did the compression test and even cold came up with the same 200psi I got warm.

At this point I'm hoping for it just being the rings carboned up, I will shorten my oil change intervals and try some cleaner before changes for the next few thousand miles and send an oil sample to verify any other potential issues. I did find out I have an extended warranty attached to my loan that has about 30k miles left so worst case I'll find a shop to sign off on a replacement engine.

 

I'd be shocked if it's carbon on the rings. Direct injection shouldn't allow that

 

Fair, if I could find a leak down tester that would have fit I would have happily done that, if anyone knows of one that fits these engines please let me know.

 

The fact it has low compression means something has happened. If the injector is seated properly, I'd I'll it's time to replace the engine. Not a whole lot you can do to replace rings on these.

Out of curiosity. How long have you owned this for? How long has this particular issue been occurring for? What happened to cause this issue?

 

The fact it has low compression means something has happened. If the injector is seated properly, I'd I'll it's time to replace the engine. Not a whole lot you can do to replace rings on these.

Out of curiosity. How long have you owned this for? How long has this particular issue been occurring for? What happened to cause this issue?

I bought the vehicle at 128k in bone stock condition with all maintenance done by a reputable dealer or local shop, it didn't have any relevant codes and wasn't smoking or had any reported oil consumption issues. I have had the oil changed once, replaced the fuel filter, and installed the emissions deletes and malone stage 2 tune at around 131k, as soon I installed the time and deletes it was smoking on first start up. I've been curious if the issue was always present but the two cats and dpf were able to mask it.

 

A reasonable train of thought and normally I would agree, when I had a 04 v70r the volvo community called it "stage 0" which was to make sure the car was up to date on maintenance and everything fixed that needed to be, I thought the maintenance records on this vehicle would save me that but hindsight is 20/20 and I must work with what I have now.

 

Lol stage 0 I like that.

Honestly I really don't see any other way around a new engine. If the injector is seated properly but compression is basically nothing, new engine.

There's no oil dilution?

 

An updates! I messaged Malone/Tunezilla after hearing that there was a patched version of the tune, got the updated tune installed and tada, no more excessive smoke on startup! I realize this does not resolve my low compression cylinder but at least my oil level isnt going up anymore.

 

I'm trying to wrap my head around how a tune is impacting your oil level, or not impacting it...