Advice Please, Identify Problem, 2007 2.2 D4d T180, Estate, Egr, Dpf?

September 12, 2015

Hi. I'm having problems with my Avensis Estate, 2007, Dcat, T180, 2.2 d4d. Please could you help identify what's causing the problem.

Symptoms:

Rough running at motorway speeds. Feels like a subtle vibration, like a muted misfire. Takes places most often at around 2,000 - 3,000 rpm, in mostly 6th gear. What's weird is that the problem is intermittent. The best way to recreate the problem is to accelerate normally through the gears to say 80mph, no problems during the acceleration, at all RPM levels.

Ease off the power upon reaching 80mph, then there is a degree of power loss with vibration. However, if you are patient and wait a moment without touching the throttle, it will recover and drive normally. However the problem is intermittent, and so may or may not return.

If I drop down to 5th gear (or lower) during the problem, the engine will recover. I have been experiencing this problem now for around 800 miles, so its not catastrophic yet, no dashboard warnings, but its very annoying and slightly stress making.

I don't see any smoke at any time, although before this problem revealed itself the car used to smell a bit "oily" after a drive, and on one occasion when sitting still in London traffic, a huge plume of smoke came out of the exhaust, and then cleared. A faulty DPF?

The problem does not occur at speeds up to 70mph.

What I've tried, and researched.

I have been searching the web for ideas and solutions. I don't feel any vibration through the clutch pedal so I don't think its related to that. Lower speed acceleration & driving is not affected, so I don't think its turbo or injector related.

However, following advice on forums I have cleaned out the EGR valve. It was packed out with soot. This cured the problem entirely for about 100 miles as I drove into London. But on my return journey, I accelerated briskly out of roundabouts etc and the problem returned. The EGR valve was still clean.

So I then created a "blank gasket" over the inlet to the EGR valve. The problem remained the same, so I assume that the EGR valve itself is not the cause. I then drove for a while at high RPM to try & activate the DPF. It didn't activate, but the VSC & TCS warning lights came on and the engine went into slow safe mode.

I removed the blank, and reset the warnings. I have just come back from a 400 mile 'round trip to Wales. The problem remains the same. At this stage, its annoying & worrying, but not inconveniencing me. What's weird is that the problem is intermittent, and sometimes recovers normally.

Could it be? What do you think?

Could it be that the DPF needs to be replaced? Is this a job that a capable "non-mechanic" could do. I see there are a few new DPF's for sale on eBay, like here for £314,

http://www.ebay.co.uk/itm/111231921987?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Or do you think the problem exists elsewhere?

Sorry for the long post.

September 12, 2015

Hi yawning dog, when the VSC and TCS lit did the MIL also illuminate? Did you read the codes or just reset, having the codes would be really handy in this situation. Without it's difficult but as a guess I'd head in the direction of an injector sticking which would reveal at part throttle more than full and result in poor atomisation and tough running. The DPF will try to clean it up but will itself be overwhelmed and possibly overheat during regeneration. If I were in your position though, I'd read the codes and go from there.

September 13, 2015

Thanks Duggerz. The MIL didn't illuminate. Unfortunately I just reset, I didn't get the codes. I have since run a can of EGR/DPF/Injector cleaner through the system, and a fuel additive. Looks like I will have to continue to monitor the situation. No further dashboard warning signs at the moment.