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2.0 D-cat 2003 T-spirit - Smoking


rkdl28
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Hello all. Fantastic and very useful forum...wish I'd found it years ago! I bought a 2.0 D-Cat Avensis a few months ago. My problem is one of recurring smoke, usually on the motorway that lasts for a few seconds, stops and then returns every ten seconds or so. It only seems to occur when the engine is warm and around the 50-70 MPH mark. It only stops when I hit the accelerator and sometimes just disappears altogether. The car runs fine otherwise but the sheer amount of smoke is embarrassing now the mornings and nights are getting lighter! I've read several topics that suggest the EGR valve but the info is about D4Ds and I can't seem to locate it on this engine. I've had a service and tried some Redex but to no avail. The car has just passed the 90000 mark. Any tips would be greatly appreciated.

Rob.

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Hello all. Fantastic and very useful forum...wish I'd found it years ago! I bought a 2.0 D-Cat Avensis a few months ago. My problem is one of recurring smoke, usually on the motorway that lasts for a few seconds, stops and then returns every ten seconds or so. It only seems to occur when the engine is warm and around the 50-70 MPH mark. It only stops when I hit the accelerator and sometimes just disappears altogether. The car runs fine otherwise but the sheer amount of smoke is embarrassing now the mornings and nights are getting lighter! I've read several topics that suggest the EGR valve but the info is about D4Ds and I can't seem to locate it on this engine. I've had a service and tried some Redex but to no avail. The car has just passed the 90000 mark. Any tips would be greatly appreciated.

Rob.

hi mate

i feel i had similar before on other car.

ok physically this means:

- SCV is/are about to die + play with you (possible el coil issue)---> result ---- give or not diesel into the HP pump + power fall. when engine is heated -- this accelerate contacts loosing + play with you again;

- Injectors solenoids (the same problem or control problem);

- Injection jet quality due to purity of diesel -- in other worrds -- a small mechanical part might be variably remained in the diesel supply canal before nozzle and when needle valve is oppened this piece might go under the needle valve and wise -- resulting good/bad injection = play with power (smoke);

Inspect fine fuel filter or change it carefully;

- EGR valve (i do not conside so)

Chers/Igor

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Hello all. Fantastic and very useful forum...wish I'd found it years ago! I bought a 2.0 D-Cat Avensis a few months ago. My problem is one of recurring smoke, usually on the motorway that lasts for a few seconds, stops and then returns every ten seconds or so. It only seems to occur when the engine is warm and around the 50-70 MPH mark. It only stops when I hit the accelerator and sometimes just disappears altogether. The car runs fine otherwise but the sheer amount of smoke is embarrassing now the mornings and nights are getting lighter! I've read several topics that suggest the EGR valve but the info is about D4Ds and I can't seem to locate it on this engine. I've had a service and tried some Redex but to no avail. The car has just passed the 90000 mark. Any tips would be greatly appreciated.

Rob.

hi mate

i feel i had similar before on other car.

ok physically this means:

- SCV is/are about to die + play with you (possible el coil issue)---> result ---- give or not diesel into the HP pump + power fall. when engine is heated -- this accelerate contacts loosing + play with you again;

- Injectors solenoids (the same problem or control problem);

- Injection jet quality due to purity of diesel -- in other worrds -- a small mechanical part might be variably remained in the diesel supply canal before nozzle and when needle valve is oppened this piece might go under the needle valve and wise -- resulting good/bad injection = play with power (smoke);

Inspect fine fuel filter or change it carefully;

- EGR valve (i do not conside so)

Chers/Igor

Thanks Mate. Bit too technical for me but I'll pass it onto 'my mechanic' and see whats what. Many thanks. I don't know if it's a symptom but my fuel economy seems quite poor. I ran a 1.8 vvti petrol for 3 years which seemed to cost me less in fuel bills than a 2.0 diesel.

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Hello all. Fantastic and very useful forum...wish I'd found it years ago! I bought a 2.0 D-Cat Avensis a few months ago. My problem is one of recurring smoke, usually on the motorway that lasts for a few seconds, stops and then returns every ten seconds or so. It only seems to occur when the engine is warm and around the 50-70 MPH mark. It only stops when I hit the accelerator and sometimes just disappears altogether. The car runs fine otherwise but the sheer amount of smoke is embarrassing now the mornings and nights are getting lighter! I've read several topics that suggest the EGR valve but the info is about D4Ds and I can't seem to locate it on this engine. I've had a service and tried some Redex but to no avail. The car has just passed the 90000 mark. Any tips would be greatly appreciated.

Rob.

hi mate

i feel i had similar before on other car.

ok physically this means:

- SCV is/are about to die + play with you (possible el coil issue)---> result ---- give or not diesel into the HP pump + power fall. when engine is heated -- this accelerate contacts loosing + play with you again;

- Injectors solenoids (the same problem or control problem);

- Injection jet quality due to purity of diesel -- in other worrds -- a small mechanical part might be variably remained in the diesel supply canal before nozzle and when needle valve is oppened this piece might go under the needle valve and wise -- resulting good/bad injection = play with power (smoke);

Inspect fine fuel filter or change it carefully;

- EGR valve (i do not conside so)

Chers/Igor

Thanks Mate. Bit too technical for me but I'll pass it onto 'my mechanic' and see whats what. Many thanks. I don't know if it's a symptom but my fuel economy seems quite poor. I ran a 1.8 vvti petrol for 3 years which seemed to cost me less in fuel bills than a 2.0 diesel.

no problem

feel free to ask as many question as you have it in your mind. yes even though the diesel engine consumes less of fuel -- but the maintenance of it must be strictly scheduled otherwise many issues are arised.

cheer/Igor

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  • 3 weeks later...
Hello all. Fantastic and very useful forum...wish I'd found it years ago! I bought a 2.0 D-Cat Avensis a few months ago. My problem is one of recurring smoke, usually on the motorway that lasts for a few seconds, stops and then returns every ten seconds or so. It only seems to occur when the engine is warm and around the 50-70 MPH mark. It only stops when I hit the accelerator and sometimes just disappears altogether. The car runs fine otherwise but the sheer amount of smoke is embarrassing now the mornings and nights are getting lighter! I've read several topics that suggest the EGR valve but the info is about D4Ds and I can't seem to locate it on this engine. I've had a service and tried some Redex but to no avail. The car has just passed the 90000 mark. Any tips would be greatly appreciated.

Rob.

hi mate

i feel i had similar before on other car.

ok physically this means:

- SCV is/are about to die + play with you (possible el coil issue)---> result ---- give or not diesel into the HP pump + power fall. when engine is heated -- this accelerate contacts loosing + play with you again;

- Injectors solenoids (the same problem or control problem);

- Injection jet quality due to purity of diesel -- in other worrds -- a small mechanical part might be variably remained in the diesel supply canal before nozzle and when needle valve is oppened this piece might go under the needle valve and wise -- resulting good/bad injection = play with power (smoke);

Inspect fine fuel filter or change it carefully;

- EGR valve (i do not conside so)

Chers/Igor

Thanks Mate. Bit too technical for me but I'll pass it onto 'my mechanic' and see whats what. Many thanks. I don't know if it's a symptom but my fuel economy seems quite poor. I ran a 1.8 vvti petrol for 3 years which seemed to cost me less in fuel bills than a 2.0 diesel.

no problem

feel free to ask as many question as you have it in your mind. yes even though the diesel engine consumes less of fuel -- but the maintenance of it must be strictly scheduled otherwise many issues are arised.

cheer/Igor

Hello. A quick update! I've had the car 'plugged in' but no faults are shown at all. I'm wondering if it is anything to do with the D-Cat system? The situation is definitely getting worse. Almost always, when the engine is warm I'm getting large blue/grey plumes of smoke every ten seconds that people behind me are now swerving to avoid! Does anyone know the location of the EGR valve on a D-Cat just so I can check it? Help!

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Hello all. Fantastic and very useful forum...wish I'd found it years ago! I bought a 2.0 D-Cat Avensis a few months ago. My problem is one of recurring smoke, usually on the motorway that lasts for a few seconds, stops and then returns every ten seconds or so. It only seems to occur when the engine is warm and around the 50-70 MPH mark. It only stops when I hit the accelerator and sometimes just disappears altogether. The car runs fine otherwise but the sheer amount of smoke is embarrassing now the mornings and nights are getting lighter! I've read several topics that suggest the EGR valve but the info is about D4Ds and I can't seem to locate it on this engine. I've had a service and tried some Redex but to no avail. The car has just passed the 90000 mark. Any tips would be greatly appreciated.

Rob.

hi mate

i feel i had similar before on other car.

ok physically this means:

- SCV is/are about to die + play with you (possible el coil issue)---> result ---- give or not diesel into the HP pump + power fall. when engine is heated -- this accelerate contacts loosing + play with you again;

- Injectors solenoids (the same problem or control problem);

- Injection jet quality due to purity of diesel -- in other worrds -- a small mechanical part might be variably remained in the diesel supply canal before nozzle and when needle valve is oppened this piece might go under the needle valve and wise -- resulting good/bad injection = play with power (smoke);

Inspect fine fuel filter or change it carefully;

- EGR valve (i do not conside so)

Chers/Igor

Thanks Mate. Bit too technical for me but I'll pass it onto 'my mechanic' and see whats what. Many thanks. I don't know if it's a symptom but my fuel economy seems quite poor. I ran a 1.8 vvti petrol for 3 years which seemed to cost me less in fuel bills than a 2.0 diesel.

no problem

feel free to ask as many question as you have it in your mind. yes even though the diesel engine consumes less of fuel -- but the maintenance of it must be strictly scheduled otherwise many issues are arised.

cheer/Igor

Hello. A quick update! I've had the car 'plugged in' but no faults are shown at all. I'm wondering if it is anything to do with the D-Cat system? The situation is definitely getting worse. Almost always, when the engine is warm I'm getting large blue/grey plumes of smoke every ten seconds that people behind me are now swerving to avoid! Does anyone know the location of the EGR valve on a D-Cat just so I can check it? Help!

Just a thought, does this engine have the "fifth injector" that controls emmisions (I am led to believe)? If so it could have some bearing on the problem.

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What's your oil consumption like

Is your coolant level still at max

And if you can remember, what rpm are you travelling at typically, when this happens?

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Did D-Cat and the 5th Injector exist in 2003?

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What's your oil consumption like

Is your coolant level still at max

And if you can remember, what rpm are you travelling at typically, when this happens?

Thanks for the quick replies everyone. My oil levels seem ok with no discernable loss of oil. I'll check the coolant tomorrow and i think the revs would be about 1500 to 2500 roughly. It happens only in 4th or 5th gear normally when cruising above 40MPH. I've noticed if I either take my foot off the gas or quickly accelerate it soon clears. The car seems to be running fine so its very confusing!

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What's your oil consumption like

Is your coolant level still at max

And if you can remember, what rpm are you travelling at typically, when this happens?

Thanks for the quick replies everyone. My oil levels seem ok with no discernable loss of oil. I'll check the coolant tomorrow and i think the revs would be about 1500 to 2500 roughly. It happens only in 4th or 5th gear normally when cruising above 40MPH. I've noticed if I either take my foot off the gas or quickly accelerate it soon clears. The car seems to be running fine so its very confusing!

Based on what you have said it sounds like soot being burn't off in the DPF. Providing the smoke defiantly isn't distinctly blue.

The filter removes soot from the exhaust gas by heating the exhaust to about 400 degrees C using burn't diesel fuel and natural source of oxygen in the exhaust. The DPF sensor's constantly monitor back pressure in the exhaust to know when to trigger a regeneration cycle when reaching capacity. They favour certain temperatures to begin a re-gen if they detect that the filter is reaching capacity. And it happens a lot more frequently when at capacity and after cold morning starts.

If you are doing 2k + RPM the exhaust temperature is likely to be getting quite high, a lot higher than 1.5k RPM especially if you hold onto 2k+ RPM. With this extra heat a re-gen can be triggered because less extra fuel is required to burn off the excess soot and the engine management see's this as favourable because surplus heat already exists.

This might happen if your running max cylinder pressure or 2k+ RPM just before the engine is warm. You may also hit a point where the water vapour in the exhaust turns into steam and exists with the burn't soot to give a more dramatic effect.

Taking your foot off the throttle can reduce back pressure in the exhaust which is constantly being monitored. When off the accelerator the reduction in combustion means a reduction in exhaust pressure from the exit valves of the pistons. Therefore cutting down on the regeneration and you will see the smoking stop.

When up to operating temperature the exhaust temperature gradually rises and active re-gens occur which you don't notice. But from cold, the EGR is most active and a lot more soot is created. This soot is then trapped in the DPF. If the DPF is near saturation, as soon as you encounter engine load (uphill) and/or 2k+ RPM after cold or low speed driving the temperature suddenly rises and can trigger this re-gen which creates white plumes of smoke.

The answer? Well, you could try keeping it under 2k RPM and light throttle loads until fully warm. And don't boot it uphill. If the DPF is saturated i would be inclined to take it on a run and keep the revs between 2k and 2.5k for the whole duration with some red line visits and some gradual full throttle blasts. You might get plenty of smoke but the idea of this run is to help the system shift some soot. Diesel's also like load so avoid light throttle acceleration over 2k. It will most likely create a lot of unburn't fuel. Its likes a fairly hard press to get up to speed.

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What's your oil consumption like

Is your coolant level still at max

And if you can remember, what rpm are you travelling at typically, when this happens?

Thanks for the quick replies everyone. My oil levels seem ok with no discernable loss of oil. I'll check the coolant tomorrow and i think the revs would be about 1500 to 2500 roughly. It happens only in 4th or 5th gear normally when cruising above 40MPH. I've noticed if I either take my foot off the gas or quickly accelerate it soon clears. The car seems to be running fine so its very confusing!

Based on what you have said it sounds like soot being burn't off in the DPF. Providing the smoke defiantly isn't distinctly blue.

The filter removes soot from the exhaust gas by heating the exhaust to about 400 degrees C using burn't diesel fuel and natural source of oxygen in the exhaust. The DPF sensor's constantly monitor back pressure in the exhaust to know when to trigger a regeneration cycle when reaching capacity. They favour certain temperatures to begin a re-gen if they detect that the filter is reaching capacity. And it happens a lot more frequently when at capacity and after cold morning starts.

If you are doing 2k + RPM the exhaust temperature is likely to be getting quite high, a lot higher than 1.5k RPM especially if you hold onto 2k+ RPM. With this extra heat a re-gen can be triggered because less extra fuel is required to burn off the excess soot and the engine management see's this as favourable because surplus heat already exists.

This might happen if your running max cylinder pressure or 2k+ RPM just before the engine is warm. You may also hit a point where the water vapour in the exhaust turns into steam and exists with the burn't soot to give a more dramatic effect.

Taking your foot off the throttle can reduce back pressure in the exhaust which is constantly being monitored. When off the accelerator the reduction in combustion means a reduction in exhaust pressure from the exit valves of the pistons. Therefore cutting down on the regeneration and you will see the smoking stop.

When up to operating temperature the exhaust temperature gradually rises and active re-gens occur which you don't notice. But from cold, the EGR is most active and a lot more soot is created. This soot is then trapped in the DPF. If the DPF is near saturation, as soon as you encounter engine load (uphill) and/or 2k+ RPM after cold or low speed driving the temperature suddenly rises and can trigger this re-gen which creates white plumes of smoke.

The answer? Well, you could try keeping it under 2k RPM and light throttle loads until fully warm. And don't boot it uphill. If the DPF is saturated i would be inclined to take it on a run and keep the revs between 2k and 2.5k for the whole duration with some red line visits and some gradual full throttle blasts. You might get plenty of smoke but the idea of this run is to help the system shift some soot. Diesel's also like load so avoid light throttle acceleration over 2k. It will most likely create a lot of unburn't fuel. Its likes a fairly hard press to get up to speed.

Thanks OldSkoO1 for the detailed reply. I think I understand it all and will try your suggestions. My one concern is that I overtook a car in high revs last week and shortly after lost power and the engine management light came on (Along with the VSC and Traction control light!). Nothing showed at the garage when plugged in and its fine now. May wait until the weekend! Would this sort the problem in the long term? Is it worth cleaning the EGR valve too or is that a separate issue? Many thanks again, Rob.

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What's your oil consumption like

Is your coolant level still at max

And if you can remember, what rpm are you travelling at typically, when this happens?

Thanks for the quick replies everyone. My oil levels seem ok with no discernable loss of oil. I'll check the coolant tomorrow and i think the revs would be about 1500 to 2500 roughly. It happens only in 4th or 5th gear normally when cruising above 40MPH. I've noticed if I either take my foot off the gas or quickly accelerate it soon clears. The car seems to be running fine so its very confusing!

Based on what you have said it sounds like soot being burn't off in the DPF. Providing the smoke defiantly isn't distinctly blue.

The filter removes soot from the exhaust gas by heating the exhaust to about 400 degrees C using burn't diesel fuel and natural source of oxygen in the exhaust. The DPF sensor's constantly monitor back pressure in the exhaust to know when to trigger a regeneration cycle when reaching capacity. They favour certain temperatures to begin a re-gen if they detect that the filter is reaching capacity. And it happens a lot more frequently when at capacity and after cold morning starts.

If you are doing 2k + RPM the exhaust temperature is likely to be getting quite high, a lot higher than 1.5k RPM especially if you hold onto 2k+ RPM. With this extra heat a re-gen can be triggered because less extra fuel is required to burn off the excess soot and the engine management see's this as favourable because surplus heat already exists.

This might happen if your running max cylinder pressure or 2k+ RPM just before the engine is warm. You may also hit a point where the water vapour in the exhaust turns into steam and exists with the burn't soot to give a more dramatic effect.

Taking your foot off the throttle can reduce back pressure in the exhaust which is constantly being monitored. When off the accelerator the reduction in combustion means a reduction in exhaust pressure from the exit valves of the pistons. Therefore cutting down on the regeneration and you will see the smoking stop.

When up to operating temperature the exhaust temperature gradually rises and active re-gens occur which you don't notice. But from cold, the EGR is most active and a lot more soot is created. This soot is then trapped in the DPF. If the DPF is near saturation, as soon as you encounter engine load (uphill) and/or 2k+ RPM after cold or low speed driving the temperature suddenly rises and can trigger this re-gen which creates white plumes of smoke.

The answer? Well, you could try keeping it under 2k RPM and light throttle loads until fully warm. And don't boot it uphill. If the DPF is saturated i would be inclined to take it on a run and keep the revs between 2k and 2.5k for the whole duration with some red line visits and some gradual full throttle blasts. You might get plenty of smoke but the idea of this run is to help the system shift some soot. Diesel's also like load so avoid light throttle acceleration over 2k. It will most likely create a lot of unburn't fuel. Its likes a fairly hard press to get up to speed.

Thanks OldSkoO1 for the detailed reply. I think I understand it all and will try your suggestions. My one concern is that I overtook a car in high revs last week and shortly after lost power and the engine management light came on (Along with the VSC and Traction control light!). Nothing showed at the garage when plugged in and its fine now. May wait until the weekend! Would this sort the problem in the long term? Is it worth cleaning the EGR valve too or is that a separate issue? Many thanks again, Rob.

Limp mode which you experienced is probably a sign that then engine is soot locked / overwhelmed with soot. Possibly a stuck EGR valve due to soot and the DPF is more than likely to be saturated.

Limp mode is nothing to worry about, its just the ECU's way of protecting itself. Although it normally would give an error code.

See if the garage will clean the EGR valve AND intake manifold for you for free. If they want to charge you, there are good EGR cleaning guides on these forums.

Along with a good high-ish RPM (2.5k) heat blast up the m-way should help burn off some of the accumulated soot.

A couple of tanks of Shell v-power might not hurt either. Just might costs you a little more in MPG and actual fuel costs while you treat the problem.

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What's your oil consumption like

Is your coolant level still at max

And if you can remember, what rpm are you travelling at typically, when this happens?

Thanks for the quick replies everyone. My oil levels seem ok with no discernable loss of oil. I'll check the coolant tomorrow and i think the revs would be about 1500 to 2500 roughly. It happens only in 4th or 5th gear normally when cruising above 40MPH. I've noticed if I either take my foot off the gas or quickly accelerate it soon clears. The car seems to be running fine so its very confusing!

Based on what you have said it sounds like soot being burn't off in the DPF. Providing the smoke defiantly isn't distinctly blue.

The filter removes soot from the exhaust gas by heating the exhaust to about 400 degrees C using burn't diesel fuel and natural source of oxygen in the exhaust. The DPF sensor's constantly monitor back pressure in the exhaust to know when to trigger a regeneration cycle when reaching capacity. They favour certain temperatures to begin a re-gen if they detect that the filter is reaching capacity. And it happens a lot more frequently when at capacity and after cold morning starts.

If you are doing 2k + RPM the exhaust temperature is likely to be getting quite high, a lot higher than 1.5k RPM especially if you hold onto 2k+ RPM. With this extra heat a re-gen can be triggered because less extra fuel is required to burn off the excess soot and the engine management see's this as favourable because surplus heat already exists.

This might happen if your running max cylinder pressure or 2k+ RPM just before the engine is warm. You may also hit a point where the water vapour in the exhaust turns into steam and exists with the burn't soot to give a more dramatic effect.

Taking your foot off the throttle can reduce back pressure in the exhaust which is constantly being monitored. When off the accelerator the reduction in combustion means a reduction in exhaust pressure from the exit valves of the pistons. Therefore cutting down on the regeneration and you will see the smoking stop.

When up to operating temperature the exhaust temperature gradually rises and active re-gens occur which you don't notice. But from cold, the EGR is most active and a lot more soot is created. This soot is then trapped in the DPF. If the DPF is near saturation, as soon as you encounter engine load (uphill) and/or 2k+ RPM after cold or low speed driving the temperature suddenly rises and can trigger this re-gen which creates white plumes of smoke.

The answer? Well, you could try keeping it under 2k RPM and light throttle loads until fully warm. And don't boot it uphill. If the DPF is saturated i would be inclined to take it on a run and keep the revs between 2k and 2.5k for the whole duration with some red line visits and some gradual full throttle blasts. You might get plenty of smoke but the idea of this run is to help the system shift some soot. Diesel's also like load so avoid light throttle acceleration over 2k. It will most likely create a lot of unburn't fuel. Its likes a fairly hard press to get up to speed.

Thanks OldSkoO1 for the detailed reply. I think I understand it all and will try your suggestions. My one concern is that I overtook a car in high revs last week and shortly after lost power and the engine management light came on (Along with the VSC and Traction control light!). Nothing showed at the garage when plugged in and its fine now. May wait until the weekend! Would this sort the problem in the long term? Is it worth cleaning the EGR valve too or is that a separate issue? Many thanks again, Rob.

Limp mode which you experienced is probably a sign that then engine is soot locked / overwhelmed with soot. Possibly a stuck EGR valve due to soot and the DPF is more than likely to be saturated.

Limp mode is nothing to worry about, its just the ECU's way of protecting itself. Although it normally would give an error code.

See if the garage will clean the EGR valve AND intake manifold for you for free. If they want to charge you, there are good EGR cleaning guides on these forums.

Along with a good high-ish RPM (2.5k) heat blast up the m-way should help burn off some of the accumulated soot.

A couple of tanks of Shell v-power might not hurt either. Just might costs you a little more in MPG and actual fuel costs while you treat the problem.

Thanks so much. I'll get onto it and let you know how I get on. Probably clean it myself but may need help to locate the valve. It seems to be in a different place than on the D4D engine which is shown in another thread.

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why dont you take a picture of the engine cover off and i will point it out to u :)

No problem I'll get onto it. Many thanks

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why dont you take a picture of the engine cover off and i will point it out to u :)

No problem I'll get onto it. Many thanks

Hello again. I've taken a few pics so here goes...

Thanks in advance

post-85777-126918660944_thumb.jpg

post-85777-126918664631_thumb.jpg

post-85777-126918668258_thumb.jpg

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  • 2 weeks later...

why dont you take a picture of the engine cover off and i will point it out to u :)

No problem I'll get onto it. Many thanks

Hello again. I've taken a few pics so here goes...

Thanks in advance

Hello. I don't wish to be a nag but could anyone take a look at my pics and advise me on the egr valve? I would be very grateful. Thanks

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  • 2 weeks later...

Hello.

I have the same problem with the car and I want to know if the issue is resolved or not ...

Exasperates me smoke it ... I bought a car just because they say it's environmentally friendly, but to get beyond the smoke and tractors !!!!!!!!

Can anyone say what we do or have changed the car?? In this case I will probably not buy Toyota again.

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  • 4 months later...

Well folks, after over three months without my car and many false dawns I've been told by a diesel engine expert that I may have a crack in the turbo manifold and the noisy acceleration is the fuel pump. His advice is to get rid. I can't see an alternative so it looks like my Toyota ownership will soon be at an end (for now). I feel sick. Can't see any other option right now. Please, can someone offer any good news? Cheers. :(

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