Help With Power Loss Issue Please Guys.

[Jeff200sx]

Hey guys, I'm hoping to get some help with my good lady's car and a recent problem, 2004 avensis d4d 2.0. The car went to a local workshop for gear box and clutch, on collection there's a severe loss of power and a very slight misfire at 2500 rpm, to me it feels like the turbo is not coming on at all, the mechanic thought it may be bad diesel and recommended she refills and drives on a while. Nothing has changed, now he wants to pull injectors for cleaning or switch the turbo.... As the car drive to the workshop fine and has no other symptoms at all I'm very dubious of this assessment.

I'm of the opinion a hose or electrical connection has been left off when rebuilding the car after the gearbox change. I'm unfamiliar with these cars tho and so far have been unable to find anything obviously wrong or not connected.

I've been searching here and online for the past few days and haven't been able to find any complete diagrams of the vac/boost hose design to be able to check for a switched Pipe etc, there's no leaks in the system and no fault codes on the ecu. No smoke or bad noises and the car starts and drives.

Everything appears perfectly fine except there's zero boost and a very slow big car.

Hopefully some one can suggest a few common areas to check before it needs to go back to the garage and have more money spent on something I believe is a simple mistake on rebuilding the car.

Cheers

Jeff

[avensisd4d786]

pay attention to

25760

it goes to the MAP sensor, I left this off and had the symptoms that you have described.

[Jeff200sx]

Brilliant job, thanks for those pic's, problem is now solved, turned out to be 1 pipe disconnected and another pair **** about face.

Again thanks for the speedy reply. Now just need to get her 5th gear sorted out and the good lady will be smiling again.

[avensisd4d786]

Good work glad I could help. This fifth gear problem can be fixed whilst the gearbox is in situ but I don't get why they didn't fix or replace when the box was off whilst replacing the clutch.

what mileage is on the car?

[Jeff200sx]

Here's the rub... She got a second hand gearbox for the car and done the clutch flywheel cylinders etc etc.... Then on the first long trip out the car pops out of 5th again, the replacement box had the same problem as the original. Lucky us!!

Anyway the original box is going away to get the 5th gear replaced and then set back in. Pity the jobs having to get done twice tho.

[avensisd4d786]

was there no warranty on the used box? maybe 14/28 days

[Jeff200sx]

Yeah it was got locally so there's no issue with that side of it it's just the fact we need to pay again for fitting the original back in after getting it sorted out.

I wasn't aware it was such a common issue in these cars.

[avensisd4d786]

sometimes the popping out is caused by the linkage cables

[Jeff200sx]

Mm that's interesting.. Is it a case of lubricating them or replacing and see?

[avensisd4d786]

replace this is something I have read not experienced so I suggest you look further into first

http://www.wcengineering.com/articles/popout.html