Outer Limits 4x4 Board

BACKGROUND: Feb 2011 motor recon (by RACQ repair centre) on my 1991 Hilux SR5 4 runner 3VZ-E Hilux motor (VIN JT711VND007001479). First 1000+ km worked like a dream (although I noticed motor slightly pulling/hopping - on and off - at speed). Then suddenly at 2000+ km, motor losing revs (quickly dropping below 500 - normal idle is 700-800) and subsequently stalling at traffic lights. Also revving high between gear shifts (2nd, 3rd and 4th and staying high - e.g. at 100km speed in 4th gear revs showing 3000). Also, loss of power/torque to motor.
ACTION: Reported to recon centre, they suggested take to my regular mechanic. Mechanic fround vacuum hoses around the solonoid area incorrectly hooked up, and rectified (rerouted hoses) and replaced the green solonoid (2nd hand solonoid installed from wreckers). Issues reported to motor recon centre who denied any initial wrong routing of vaccum hoses.
OUTCOME: Worked a treat for the next week ONLY, where it was idling well at 700rpm, and power/torque restored, no excessive revs between gears or top gear (although I didn't try 5th gear as was around town driving). Then suddenly this last few days it went back to initial problem - i.e. idle drop below 500 and stalling, but seemingly not doing it all the time, although I've only done short local neighbourhood trips.
ACTION: Reported again to RACQ recon centre, again they said take to my mechanic. Mechanic adjusted idle up but this did not help. He was then unsure of problem now, but suggested it may be EGR Vacuum may be clogged with carbon build up. He suggested I get RACQ recon centre to clean it/sand blast (which I thought they should have done in the rebuild anyhow???) OR to close of the EGR gasket intake to motor head and see if that makes a difference (to rule it out as a problem). I've done none of this yet, as I have also noticeD the FUEL REGULATOR is ticking loudly (but can't remember if it always did this?). Perhaps this is fuel problem???? BTW I run only 98 unleaded premium fuel.

I NEED TO GET THIS RECTIFIED FOR A 2-3 WEEK TRIP THROUGH MID WEST NSW IN 2 WEEKS TIME. ITS USING FUEL LIKE CRAZY AS WELL!

ANY IDEAS OR ADVICE WHAT PROBLEM IS V. APPRECIATED? WHO BEST TO TAKE IT TO WHO CAN DIAGNOSE WHATS WRONG? Mechanic and recon centre are clueless... strange thing is it didn't happen for the first 1000+km after rebuilt motor (despite hoses on the wrong way then).
THANKS...

This guy had the same ish issues and fixed it fairly easily,

http://www.4wdaction.com.au/forum/viewt ... 3&t=107237" onclick="window.open(this.href);return false;

Thanks Sruth, but your link takes me to a blank forum board 4WD action - can you send the specific link or tell me topic heading to search for on that site? Thanks...

Sorry Struth I realised I have to register on that site, done so now, awaiting administrator to approve. Meantime can you tell me what the easy solution was???

Copied the important bit from that thread....


 Re: 4runner V6 3VZ-E fuel economy help ?????
update for anyone thats interested, have now fitted a new oxygen sensor and also a new coolant temp sensor plus new plugs, $230 later and im now getting just over 400kms to a tank
Happy days


Your mechanic should be able to test these components to see if they have failed or not. Have them check your air flow meter also.

Thanks Ray185 for your tips. My mechanic does not seem to want to invest in rectifying the issue, so I'm going to take to Toyota direct to check upon your suggested faults. Thanks again...