Outer Limits 4x4 Board

hilux help needed please

2004 2KD-D4D (yup itsa a 2.5 diesel)

symptoms - No power - cannot get over 3,000rom and it is real SLOOOOOOOOOOOOOOOOOOOW to get up to 3000rpm. 4000 is impossible. its even slower than my old LC II with the 3L so its real SLOW hahahaha.

I have cleaned the injectors and new diesel filter since our diesel is so filthy

There is no turbo cutting in whatsoever. I now an=m going to put a boost gauge on it to see how bad it is.

Today we removed the O2 sensor and there is no effect the . Its only a piece of plastic?

We took it to a mekanik and they plugged the electric doctor into it. Nothing wrong :(

The only problems it can be
1. O2 sensor not working?
2. ECU needs to be remapped?
3. Turbo has died?

it is booked to go to a tuning shop to see whatz wrong and have a chip and intercooler installed at the same time any advice I can be given before we take it there would be wonderful.

anything else?

Its a D4D and it doesnt have an intercooler?

Whatever you do dont let them screw around fitting stuff to it til its running right.

I dont think these run like the old days, ie if the turbo dies it continues pumping in lots of juice and hence black smoke. There'll be some stupid sensor compensating for it.

Look at the turbo first and other obvious things first.

Yup the Malaysian Model D4D 2KD does not come with intercooler presumably to keep costs down

The THAI one has 3.0 1KD D4D with intercooler. :(

Yers I beleieve the turbo is dead now i need to find a good shop to fix it since its the handbag car.

Bad air mass meters can give low power issues. Basics need to be checked before anything else is done. This includes rail pressure check, boost pressure, egr operation, exhaust restriction.


Andy

Ok more help needed please.

I took the air flow meter out the other week and tried it - wow not one bit of difference to the vehicle - same flat drive.

So I cleaned the diesel of the Air flow sensor then put it back in - wow suddenly I had a TURBO back but the engine still not responding fast.

So saturday took the the mekanik we spent 90 minutes - checked BOOST and attached a boost gauge to it and drove it round - its running at 6PSI from 2000-4000 rpm constant with air filter or without.

Waste gate opening correctly at around 6+psi

Mekanik shaking his head also.

the electronic box shows nothing wrong.

No black smoke even when you floor it. Its like the turbo actuator dectector is not pumping fuel in.

I have 3 washers to stick into the wastegate to try and lift the boost by 2 pounds to 8PSI.

Very frustrating.

next will be rail pressure but all the injectors have just been cleaned and checked. Exhaust restriction the truck is stock.

Any more clues - ECU lost mapping?

Its going to the speed shop for a chip upgrade and intercooler to be fitted but I do not want to do this until fix this problem first.

the Engine is 2KD-FTV D4D

Anyone know what the max stock BOOST is for a 1KD-FTV or a 2KD-FTV as they are the same engine except for the BORE. It ifts 6PSI thent he turbo is running fine else its slightly sick.

replace the MAF sensor. it could have gone bad.
the other thing is the fuel pressure sensor.

You didnt suck in part of the air filter?

Waste Gate remaining open?

Turbo knackered?

My understanding of these engines is that the turbo is a vnt type. 6psi is too low on any modern diesel. 1kdftv in hiluxes here run up to 16psi, have about 12 at 1800rpm.

What rail pressure do you have? Why were the injectors cleaned and how did they do it? There are only 3 people I know of in Oz that have the equipment to fully dismantle clean and retest Denso common rail injectors.

Andy

Unbelievable

The issue has been resolved

It would not rev over 3,000 and SLOWWWWWWWWWWWWWWW and no turbo boost and you could smell the unburnt diesel.

Into the workshop - nothing the electric diagnostic brain ses the car is fine hahaah. Stupid BRain its not driving it.

So one sunday afternoon with nothing to do we started with the basics - what did the last mekanik do when they pulled the injectors out to clean them. They removed the air cleaner they had to and other parts.

we went through the list MAF, Air FLow sensor, Turbo, Diesel Filter, air filter.

Removed the Air Flow sensor as that was in the air filter hose cleaned all the diesel of it and put it back but did not connect the wires - test drive and no change absolutely the same. Connected the wires back and then drove it in the morning it what a transformation suddenly the turbo was back - but its still a 2KD-FTV HILUX and no power. Looks like the mekanic when he put the injectors in they did not connect the air flow sensor up correctly :( .

A trip to RAWANG hospital checked everything again and the air filter etc was checked and the TURBO boost - all running fine.

I talked to Josh from Millenium Motors and we discusssed CHIPing and intercooler and lifting the boost.

Before I had it all done I took it to toyota to check the rail pressure , the injectors and the turbo presssure. All factory numbers still was what they told me. A later check revealed the tiny turbo runs a massive 6lb of boost from 2000 to 4000 rpm .

Millenium Motors dynoed the engine and wow a massive 50hp at the wheels.

THe chip was fitted along (and we set it to 20 extra hp) with a vavle to set the boost to 9lb however until we remove the factory wastegate and fit a OEM one it will race to 9 and drop back to 6lb very quickly.

THe dyno revealed 20extra hp at the wheels 400 revs earlier and max torque at 3800 revs after that no point in revving it anymore. The little HILUX Vigo is transformed to something worth driving.

Next is the intercooler and the OEM wasteagte and thats it finished driveable and nice. Pity the stupid HILUX auto issue of slowness of the mark is still there but thats a MAlaysia AUTO HILUX issue.


I am only going to add intercooler and remove the factory wastegate - I am only going to boost it to 10-12 PSI thats it.

I am not modifying the TURBO unless it breaks The transmission is like a wetpaper bag (i.e. USELESS for performance or pushing any power through it.)

RED is my TOY (21PSI BOOST in a 13B-T etc). This (the HILUX) is my HANDBAG fishing wagon along with the ISUZU they are for comfortable reliable customer transport not for HOONING.

The first thing you notice is you no longer need to slam your foot down to make it kick down to get it to get up and go - A gentle prod on the go faster pedal is met with a little shove back in the seat and off it goes happily pulling away something it used to strugle to do. Hence less REVS=LESS FUEL=SMOOTHER DRIVING STYLE.

Also a DYNAMICS DYNO will read lower HORSEPOWER than most other DYNO's but it supposedly a truer reading than other models of DYNO meters.

In the end I took it back tot he shop where they stuck the brain into the ECU and tossed them the keys and said here drive this - they finished the test drive and interrogated me as to what I did hahaha as thjey have a previous model SR5 Hilux (2KD also) with exactly the same problems I had in the workshop and they cannot fix it.


THank for the input to what was wrong very helpful.