Intermittent 'large Fuel Leak Detected' - Help Welcomed

[hipwit]

My Toyota Avensis Diesel (53 plate) cuts out on me occasionally. The engine goes into safe mode, but is fine when I switch the engine off and on again. The diagnostic light comes on, but then resets itself again – sometimes quickly, sometimes within a couple of days. When it’s on, I get P0093 – large fuel leak detected. There is no fuel leak. In trying to fix this fault, the fuel pump has been replaced, as has the common diesel rail. The air filter is fine, and the EGR valve has been checked and is fine also. However, the fault still occurs – but intermittently. It’s been fine for 9 months, but is now back. Sometimes. Latest diagnosis says ‘Injector 2’ is out of parameters, so the recommendation is to replace ALL the injectors. Does this fault sound consistent with an injector problem. Bearing in mind a) it is very intermittent, and there might be months between incidents B) it only seems to happen at the beginning of journeys when the engine is cold? I don’t really want to replace all the injectors (seems an expensive overkill, and the garage won’t guarantee it will fix the fault) and am not totally convinced, because of its intermittent nature, that it’s an injector issue anyway. Any thoughts welcomed and appreciated.

[Jamesbelfast]

If a faulty injector sticks in the open postion then the fuel rail will not be able to maintain pressure - hence the ECU thinks there is a fuel link. It may be possible to have the injectoirs cleaned and tested or repaired at much less cost than replacing them. I suggest you contact a diesel specialist for further advice as very few garages will have the necessary equipment or skills for this type of work. Ideally it is best to ensure all injectors are either replaced or refurbished at the same time as over time injectors tend to deteriorate and if one is better than the other then the engine may run erratic or show up as a fault on the ECU. I wouldn't recommend driving the car unecessarily as a constant leaking injector can wash the lube oil out of the cylinder leading to accelerated cylinder and piston wear.:)

[t-spiritpete]

If a faulty injector sticks in the open postion then the fuel rail will not be able to maintain pressure - hence the ECU thinks there is a fuel link. It may be possible to have the injectoirs cleaned and tested or repaired at much less cost than replacing them. I suggest you contact a diesel specialist for further advice as very few garages will have the necessary equipment or skills for this type of work. Ideally it is best to ensure all injectors are either replaced or refurbished at the same time as over time injectors tend to deteriorate and if one is better than the other then the engine may run erratic or show up as a fault on the ECU. I wouldn't recommend driving the car unecessarily as a constant leaking injector can wash the lube oil out of the cylinder leading to accelerated cylinder and piston wear.:)

The advice from James is spot on but if you do remove the injectors PLEASE mark them up as 1,2,3,4 as they MUST go back in the same cylinder from where they came, also any replacements will need reprogramming.

I suggest you go to a good diesel injection company to get it fixed as this may save you ££££££'s rather than using a main dealer. ;)

[hipwit]

If a faulty injector sticks in the open postion then the fuel rail will not be able to maintain pressure - hence the ECU thinks there is a fuel link. It may be possible to have the injectoirs cleaned and tested or repaired at much less cost than replacing them. I suggest you contact a diesel specialist for further advice as very few garages will have the necessary equipment or skills for this type of work. Ideally it is best to ensure all injectors are either replaced or refurbished at the same time as over time injectors tend to deteriorate and if one is better than the other then the engine may run erratic or show up as a fault on the ECU. I wouldn't recommend driving the car unecessarily as a constant leaking injector can wash the lube oil out of the cylinder leading to accelerated cylinder and piston wear.:)

Thanks for this, sound advice. I've chucked so much at this, this will be my last shot, but I feel I'm narrowing in on the problem. Many thanks.

[igormus]

My Toyota Avensis Diesel (53 plate) cuts out on me occasionally. The engine goes into safe mode, but is fine when I switch the engine off and on again. The diagnostic light comes on, but then resets itself again – sometimes quickly, sometimes within a couple of days. When it’s on, I get P0093 – large fuel leak detected. There is no fuel leak. In trying to fix this fault, the fuel pump has been replaced, as has the common diesel rail. The air filter is fine, and the EGR valve has been checked and is fine also. However, the fault still occurs – but intermittently. It’s been fine for 9 months, but is now back. Sometimes. Latest diagnosis says ‘Injector 2’ is out of parameters, so the recommendation is to replace ALL the injectors. Does this fault sound consistent with an injector problem. Bearing in mind a) it is very intermittent, and there might be months between incidents B) it only seems to happen at the beginning of journeys when the engine is cold? I don’t really want to replace all the injectors (seems an expensive overkill, and the garage won’t guarantee it will fix the fault) and am not totally convinced, because of its intermittent nature, that it’s an injector issue anyway. Any thoughts welcomed and appreciated.

hi mate

the rail has pressure sensor that might give you a wrong signal due to either poor contact or contact dirty. You ve to be careful with this code P0093 -- your injectors are located under the cover and even this fuel leaf is in fact available confirmed by this pressure sensor -- you can't see this possible leak from fuel pipes connections under this cover and this diesl will be mixed with lube oil resulting viscosity drop. You should conside the above. Cheers/Igor

[Dromore]

Hi,

I cannot help as I have the same problem! but I have replaced the 4 injectors, the common rail, Denso fuel pump and fuel filter and still this problem occurs.

Therefore the injectors may no fix yours

Has anyone experienced this problem and any ideas how to fix it.

[igormus]

Hi,

I cannot help as I have the same problem! but I have replaced the 4 injectors, the common rail, Denso fuel pump and fuel filter and still this problem occurs.

Therefore the injectors may no fix yours

Has anyone experienced this problem and any ideas how to fix it.

hi mate

why did you change all injetors without reason found and even fuel pump??

each fuel injector has return line and in case the needle valve of each injector has extensive gaps between needle and seat case -- this might lead to loosing of fuel pressure + the rail presure sensor gives a signal stated by the author. Cheers/Igor

[Beagh1958]

To hipwit & Dromore,

As igormus suggests you need to be careful with this code, as it denotes a few faults under the one code. First fuel pressure sensor (could be registering false fault ie: sensor duff), wiring circuit for above sensor & the biggy, covers all faults, mechanical component at fault. Hope this has not created more questions than answers.

Good Luck, Regards, Beagh.

[Dromore]

Beagh/Igormus,

Thanks.

By replacing the common rail the presure switch is replaced, all mechnical parts replaced and still the fault occurs.

I have checked electric connections and now considering checking or replacing the engine wiring harness. Do you think there is any other thing I should try first.

Regards

Dromore

[igormus]

Beagh/Igormus,

Thanks.

By replacing the common rail the presure switch is replaced, all mechnical parts replaced and still the fault occurs.

I have checked electric connections and now considering checking or replacing the engine wiring harness. Do you think there is any other thing I should try first.

Regards

Dromore

OK -- Good -- the code P0093 still plays with us :)

Look -- each pump, i mean HP fuel injectionpump must to have own safety valve to prevent pump from damage by hydraulic pressure -- it is normal arrangement for pump. Now let's imagine that during fuel filter changing inaccurately -- you could remain (ocasualy) mechanical dirt inside and that was sucted into the pump. What is going on after --- a small piece could be under the delivery valve -- it is one way. As to another -- the safety valve might to havve not good sealing resulting pressure dropping + giving you this P0093. As I caught you have changed pump as well -- maybe the staff installed it inaccuratety.

Please conside the aforesaid. Cheers/Igor

Do not give up !!!

[toyotairl1983]

Hi,

I cannot help as I have the same problem! but I have replaced the 4 injectors, the common rail, Denso fuel pump and fuel filter and still this problem occurs.

Therefore the injectors may no fix yours

Has anyone experienced this problem and any ideas how to fix it.

hi mate

why did you change all injetors without reason found and even fuel pump??

each fuel injector has return line and in case the needle valve of each injector has extensive gaps between needle and seat case -- this might lead to loosing of fuel pressure + the rail presure sensor gives a signal stated by the author. Cheers/Igor

Hey guys,

I also have the same problem on a 03 d4d avensis. Brought it to garage who said all filter were clear and he got error code p0093 which meant a fuel leak inside the engine. The car looses power when cold and just runs at idle but when warm is fine but a bit smokey too. He also mentioned he could be a sensor on the common rail but the whole thing would need replacing costing about 80 euro plus vat. He told me today that in his professional opinion it was the injectors but he would clean out the egr valve on monday too see if that fixes it. Will update ye and let ye know how it goes. any other ideas would be helpful as i cant really afford to recondition the injectors and car would have to go off the rd.

[atopman]

Hi , seems like a common problem, i too have it exactly like above guys ..mine is 2.0d4d (54)plate. Has anyone got any updates yet? What i dont get how come the engine works perefectly after it reaches normal temperature. Are there any toyota mechanics here who can tell us the solutions to past similar faults ?

My local toyota garage says they will run a diagnostics test for £35, with this test they will tell me exactly what the fault is. They also guarantee the test to be accurate. So if i have that fault fixed, they guarantee it will be that. If it turns out not to be that, i will be covered as they misdiagnosed it. What do you guys think about that ?

[Thermal]

... will run a diagnostics test for £35 ..

I say, that's money well spent.

DTC P0093 (possibly together with a number of additional error codes) points to a failure in the high pressure fuel system.

In addition to the P0093 code, so called Freeze Frame Data is stored. These records contain the status of several fuel system components at the time the error occured.

Freeze Frame Data can be read and analysed by the Toyota handheld tester device and pin-point the exact cause of the problem after running some more tests.

This will be far cheaper than replacing non-defective parts by trial and error.

This may be irrelevant here, but I seem to remember a similar problem, where in the end the failure was cured by replacing the gasket of the fuel filling cap.

Under normal conditions, there's a vacuum inside the tank.

If the fuel cap is untight, there's no vacuum detected and the ECU became confused and suspected a leak.

That would be the cheapest ever fix.

Good luck, and post the outcome of the exercise here.

[atopman]

Just to let you know, i stopped going to my usual garage for fuel ( Shell station)

i also started used wynns diesel engine injector cleaner inside fuel, 2 bottles spread over a few months, and after a few months the light has gone, and so has the code...it has been ok now for a bout 6 months.

the cold engine revs have restored to 1200 rpm and controls down when normal temp reached...ie working as it should...hope it stays ok, maybe you guys can try this too.

[Mistermena]

Befor I read the last post I was going to say, why dont people try a fuel cleaning additive?... Its the 1st thing I'd do with BG244... Or Millers ect

[gothaminc]

Hello, this is my first contribution, and i have had the same issue with my avensis. One day while driving, it went into limp mode, and presented the fault code of large fuel leak. After changing injectors (800 quid), fuel pressure sensor, fuel pump, fuel filter, egr valve, cleaned out fuel tank for good measure, the problem was still present. What i tried one day, was disconnected the fuel TEMP sensor. The car now runs to full revs, but seems at slightly less power, but i suspect this is due to the engine light being on due to temp sensor disconnected. What puzzles me, is that the large fuel leak fault code is no longer presenting itself. BUT, if i plug the fuel temp sensor back in, the large fuel leak code reappears, and car runs in limp mode. I have changed the temp sensor, but this issue still occurs..... does anyone have any suggestions? Love the car, or should i say loved......

[USM17N]

Hi,

Did anyone try to fix this problem. 

I'm having this issue at this moment and now fed up with. 

I have changed completely everything on the engine: i.e. fuel lift pump, EGR valve, Mass airflow etc. but still no luck.

 any further suggestions?

 

[adam621]

Hi,

I was having the same problem and was looking for a solution I replaced the injectors, the common rail, fuel pump and fuel filter but the problem was still there after a hard work I found the solution.

[USM17N]

Adam, 

What was the solution?

Im still having trouble.

 

 

[Yasinlaura]

Whats solution? I am haveing same problem cold engine goes on limp mode till warm up fine after that

[USM17N]

Hi,

replace the fuel injectors or reconditioned them 

[Yasinlaura]

On 24/11/2009 at 10:51 AM, hipwit said:

My Toyota Avensis Diesel (53 plate) cuts out on me occasionally. The engine goes into safe mode, but is fine when I switch the engine off and on again. The diagnostic light comes on, but then resets itself again – sometimes quickly, sometimes within a couple of days. When it’s on, I get P0093 – large fuel leak detected. There is no fuel leak. In trying to fix this fault, the fuel pump has been replaced, as has the common diesel rail. The air filter is fine, and the EGR valve has been checked and is fine also. However, the fault still occurs – but intermittently. It’s been fine for 9 months, but is now back. Sometimes. Latest diagnosis says ‘Injector 2’ is out of parameters, so the recommendation is to replace ALL the injectors. Does this fault sound consistent with an injector problem. Bearing in mind a) it is very intermittent, and there might be months between incidents B) it only seems to happen at the beginning of journeys when the engine is cold? I don’t really want to replace all the injectors (seems an expensive overkill, and the garage won’t guarantee it will fix the fault) and am not totally convinced, because of its intermittent nature, that it’s an injector issue anyway. Any thoughts welcomed and appreciated.

I am haveing same problem now did you find out what was the problem? Thanks

[Karimvigo]

I solved the large fuel leak code on my hilux Vigo. The problem was fuel cooler was clogged. It is located under the hilux. It looks just like a transmission oil cooler only smaller. 

[Garywyatt]

I have a Toyota previa 2.0 d4d  2003 I put a 2nd hand cylinder head on it and it will not start 4 love nor money  also I bought a 2nd hand injector put it on the car still wont start or catch do injectors have to be coded also do the other injectors have to go back in there original cylinders where they came from 

[paul9]

Yes, injectors need to be coded, but I believe they should still run, but inefficiently. Look into a Techstream diagnostic system, although the Delphi system can also code your injectors. Normally, you would put the injector back into the cylinder it came from and that would avoid the need to recode the system, except for new injectors.