P2002 -- My T180 Saga Continues...

[janeko]

Hi everyone,

this is a follow up from my previous posts here:

http://www.toyotaownersclub.com/forums/topic/153592-2007-t180-loses-power-and-vsctrcmalfunction/

http://www.toyotaownersclub.com/forums/topic/153761-common-rail-for-t180-d-4d-needed/

a long story short

- it all started with fault lights and several error codes

- EGR cleaned, new batter fitted -> P0093

-> new SVC fitted, no luck was not the cause

-> common rail tested, not the problem

After many iterations and great help here , I found that Colchester Diesel were able to part test the injectors. They found back leakage was too high. Changed two injectors which were the worse.

Total bil: I don't want to think about it anymore. We have a New Year.

However, after maybe 5miles out the garage when I finally picked up the car... the good old fault lights came back. My heart sank deep down somewhere where I could not feel it anymore.

Back to T. On the way the car lost most of its power. This time code P2002 came up.

The solution suggested so far: change some pipes going into a sensor, do a regenerating clean, see what happens. The car will be booked in next week.

Any ideas or suggestions? What is T policy now? It seems (reading through old posts) that they used to change EGR valve + mainfold inlet on an extended warranty. However when I had new engine rebuild 2y ago (headgasket issue) I just had the block changed, not the EGR, D-CAT nor the 5th injector -- should these have been changed as part of the bulletin job? But I did get ECU reprogrammed then, I think.

thanks as usual

[radduu]

http://www.toyotaownersclub.com/forums/topic/143220-dpf-failing-after-160k/ you can see what I've done to mine, but with no results.... The end will consist in an emulator + extraction of the DPF.

[janeko]

http://www.toyotaownersclub.com/forums/topic/143220-dpf-failing-after-160k/ you can see what I've done to mine, but with no results.... The end will consist in an emulator + extraction of the DPF.

Thanks. That thread was very helpful indeed!

Has anyone got a copy of the bulletin EG-0061T-0712 which is mentioned there on p6 (which specifies the inspections to be made when rebuilding the AD2 engines) -- mine did not have EGR, 5th injector etc tested at all at the time.

[Devon Aygo]

The instructions state that the operation of the DPNR, MAF, 5th injector & EGR have to be checked before the engine is changed. If they are faulty at that point then they are to be repaired/replaced subject to separate TSB's which cover each individual issue. The fact that it has taken two years to manifest since the engine was changed would suggest they where all fine just because an engine is replaced it does not include automatic replacement of the DPNR, EGR etc...

( before people start posting the injectors should have been checked, they are not included on the #180 2AD-FHV engined cars )

[janeko]

Makes sense, than

The instructions state that the operation of the DPNR, MAF, 5th injector & EGR have to be checked before the engine is changed. If they are faulty at that point then they are to be repaired/replaced subject to separate TSB's which cover each individual issue. The fact that it has taken two years to manifest since the engine was changed would suggest they where all fine just because an engine is replaced it does not include automatic replacement of the DPNR, EGR etc...

Makes sense, thanks.

Any idea why this problem manifested itself right after all the previous repairs, new injectors etc? Or is that just a very unlucky coincidence?

[Devon Aygo]

The faulty injectors most likely caused poor combustion issues, poor combustion of diesel results in increased particulate matter causing blockage of EGR and increasing strain on DPNR as it tries to scrub the particulates from the exhaust gases. The use of the incorrect spec oil can also accelerate this as not using C2 low ash engine oil reduces the oil ability to contain/suspend soot within the engine oil increasing the strain on the DPNR

[radduu]

Also, if you drove the car, most time in the city, the PDF will become clogged.

[janeko]

The codes were cleared when I visited Toyota to see what the matter was (10days ago) but came back (including power loss above 2000rpm) on my way back. Rather strangely, next day the car was driving fine and the the next day the error lights went off by themselves ... and have not came back since!

Any good advise on how to keep it this way?

I put some Archoil yesterday and went for a 60miles ride. The fuel consumption seems to be a bit higher higher than previously (and mine was never particularly impressive). Driving on motorways, steady 70-80 mph mostly in sixth (with a 3min of "Italian tune up" thrown in the middle) I averaged out 33pmg where I would have expected to have around 38 or more. I doubt it's Archoil?

Could it be the new injectors or the interplay of 2 new 2 old ones? (I may also be getting false readings, will check when the tank is empty). Any ideas or known tricks to improve fuel efficiency on T180?

thanks!