Black smoke is unburned fuel caused by either overfuelling (injectors/fuel pump if not HDI) or shortage of air (turbo failure, inter cooler hoses holed or blocked air filter) These are the obvious things I would be looking for.

 

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Thanks for your replies.

Here is a quick video of what is going on.
Peugeot 206 2.0 HDI - YouTube

As you can see in the video when ever I try to rev the engine it fails to rev above 2500rpm, and I get smoke out the back of the car, and also from the back of the engine.

Disconnecting the MAF sensor does not seem to affect the running of the engine.
But disconnecting the pipe on the vacuum pump output makes the engine rev freely.

Each time this has happened it has been raining, I don't know if this might be related or not.

Any more ideas

 

If disconnecting the vac cures it then I recon your vacuum butterfly on your inlet is being pulled closed and blocking airflow.

Disconnect the thin vac pipe to it and plug with a bolt as a TEMPORARY cure.

 

A lot of smoke / fumes coming up from the back of the engine and to me sounded like an air pipe leaking. Is the turbo at the back of the engine ? Could be the intake pipe to the turbo is holed.

I'd be looking to see where the smoke was coming from. Doesn't sound like an exhaust leaking but I wouldn't want to be driving it with all that smoke under the bonnet being pulled into the car.

 

Thanks again for your time and replies.

The car seems to be running ok again this morning, but I want to get to the root of the problem and fix it.

I am lucky that each time this has happened I have been less then 3 miles away from home, so have been able to limp the car back home.

The turbo is indeed on the back of the engine.

I was not aware that the 2.0 HDI had a vacuum butterfly plate.

I have been out looking at the car this morning, and had a good look at the pipes leading from the vacuum pump.

There are two vacuum pipes leading down the back of the engine, one clearly goes to the EGR valve, and I guess the other vacuum pipe must lead down to this vacuum butterfly plate that you talk about.

When the engine is running right there is no sign of smoke coming from the back of the engine, this only happens when it's playing up. And at this point in time I have no idea where about the smoke is coming from.

Thanks again for your time.

Best Regards.

 

I have just been back out to the car again, and I have been able to recreate the above problems manually.

As said in my last post this morning the car seems to be running fine, and will rev freely and drive as normal, But if I apply a vacuum to the second vacuum pipe running down the back of the engine, the engine will not rev and poor's out smoke again.

Both times this has happened it's been raining. It's not yet happend on a dry day, So I can't rule out that water is getting into a sensor somewhere.

I am not getting any kind of warning lights up on the dashboard, and my OBDII USB cable is also not showing any faults.

So my next question is this likely to be a mechanical or electrical fault, I would really like to get down to the root curse and not just cover up the problem.

Thanks for your time.

Best Regards.

 

Just a quick update.

The fault was down to both of the Bosch 0928400414 control valves.
Both of the valves are stuck open meaning that it was causing the EGR valve to fully open, and the air doser to close.

I have now removed the control valves, and removed and blocked the EGR system.

The car is now once again running how is was before the problem started.

I am unsure why both of the control valves failed, but now I have removed the EGR system from the car they are no longer needed.