Bad Starting 2007 2.2 D4D Avensis

[andy750]

Hi all and merry christmas,

This problem has been on going for 2 weeks now and I thought I had it sorted!

The engine kept failing to start, fuel tank was full and the fuel filter was 6 months old, but on checking the filter it turned out to be dirty so the filter was changed, the car started no problem.

The next day the engine failed to start again, by this time I had a 1/4 of a tank. I decided to drain the fuel tank as best I could and blow the main fuel line with air, dirty black fuel came out.  I then replaced the fuel filter with a new one, once the new fuel filter was primed with new fuel the engine started no problem and ran well. 

The next day the engine failed to start again, this time the engine warning light came on, along with the VSC and TRC lights.  I then bought a streetwise code reader, found a fault, code P0400, it turned out to be the EGR valve which I have since cleaned today.

I started the car again with no problem, I ran the engine for a while then switched it off.  A few hours later I tried to start the engine again and I'm back to square 1.

I've since managed to start the car and I have taken the car for a drive, 2500 rpm 2nd gear and then through the gears with no problem, once I switched the engine off and tried to restart straight away the same engine starting problem occurs

This is some footage of what happening

Has anybody had this problem before, if so what did you do to solve it?

Thanks in advance

[GerryMcG]

This is exactly what my 2.0 2008 does, any advice greatly appreciated 

[andy750]

Hi Gerry and happy new year.

It seams that my car which has 160,000 is suffering from low fuel pressure, according to the live telemetry that the recovery guy showed me. He said the car gradually builds up the pressure over a period of 10 - 30 seconds before the engine will start and run without shutting down.  I have since spoken with a diesel specialist, he advised me that a lot of low fuel pressure problems occur from the fuel tank due to dirt build up, and told me to start from the fuel tank and work forward (the cheapest option first).  I drained the tank of the fuel that was left. I then cleaned the sender unit and the tank out, I was surprised how much crap was in both sender unit and tank. I cleared the main fuel and return lines and put it all back together and checked my filter again!  Thinking that the problem was solved I started the car and no problems. I then tried the next morning and the starting problem is still there. I have checked the common rail and cleaned the injector pipes, (No Joy). The car is now going to the garage tomorrow morning for electrical testing. I think it be the pressure sensor, I was unable to test it as I couldn't remove the !Removed! thing from the common rail. I have removed the SCV and cleaned that as well.

[John Kennedy]

Scv - Suction control valve is a weakness on these. They have been upgraded by Toyota,and now come in a larger diaphragm with an attachment. They are Pricey, but you can get after market ones cheaper with warranty. The longer diaphragm design is meant to be problem free. You can also take it out and clean it. Check for scoring on the shaft. Use 2000 grit to remove scoring marks, or replace. It's just a spring loaded mechanism inside. They can become stuck. Check with a multimeter if necessary 

[2009joe]

On 1/1/2018 at 7:29 PM, andy750 said:

Hi Gerry and happy new year.

It seams that my car which has 160,000 is suffering from low fuel pressure, according to the live telemetry that the recovery guy showed me. He said the car gradually builds up the pressure over a period of 10 - 30 seconds before the engine will start and run without shutting down.  I have since spoken with a diesel specialist, he advised me that a lot of low fuel pressure problems occur from the fuel tank due to dirt build up, and told me to start from the fuel tank and work forward (the cheapest option first).  I drained the tank of the fuel that was left. I then cleaned the sender unit and the tank out, I was surprised how much crap was in both sender unit and tank. I cleared the main fuel and return lines and put it all back together and checked my filter again!  Thinking that the problem was solved I started the car and no problems. I then tried the next morning and the starting problem is still there. I have checked the common rail and cleaned the injector pipes, (No Joy). The car is now going to the garage tomorrow morning for electrical testing. I think it be the pressure sensor, I was unable to test it as I couldn't remove the !Removed! thing from the common rail. I have removed the SCV and cleaned that as well.

how did so much dirt get in to the tank 

[Catlover]

40 minutes ago, 2009joe said:

how did so much dirt get in to the tank 

The guy you asking that question, andy750, has not been on the forum since Jan 1 2018. Probably unlikely he will reply.

[jimtaxi]

I had almost identical symptoms with a 2.2 D4D 2008. After about 9 months of garages telling what they thought (it never was what they thought) I was driving along and the Battery light came on for a few miles then went off. I called out AA next time it happened and the AA mechanic said he had seen this before and added "was I having starting problems". The car went in for an alternator change which was quite expensive. However the car ran for a further 120000 mls with no starting issues even in -15 winter. In fact when it was traded in at 240000 it was running great.(it was a taxi). Dont know if this is whats wrong with yours but worth investigating. My car also up until the alternator was changed was eating batteries at a rate on one a year this stopped as well.

[2009joe]

20 minutes ago, jimtaxi said:

I had almost identical symptoms with a 2.2 D4D 2008. After about 9 months of garages telling what they thought (it never was what they thought) I was driving along and the battery light came on for a few miles then went off. I called out AA next time it happened and the AA mechanic said he had seen this before and added "was I having starting problems". The car went in for an alternator change which was quite expensive. However the car ran for a further 120000 mls with no starting issues even in -15 winter. In fact when it was traded in at 240000 it was running great.(it was a taxi). Dont know if this is whats wrong with yours but worth investigating. My car also up until the alternator was changed was eating batteries at a rate on one a year this stopped as well.

dam thats good to know id thought those Battery and alternator  testers would find that problem im guessing the alternator either was charging up your Battery way to much or not enough. on my last car i servsed my altinator myself by putting in a new replacement  brushes regulator which was not a big deal at all same goes for the starter on the 1.9tdi i serviced that also myself another easy job im hoping that these toyota avensis starter and alternator is easy fixes also by just ordering replacement parts online. its interesting when you say that as my brother had one of the old for focus 1.9tddi great car and didn't give much bother and trust me did alot of miles with no bother  but he had a really bad starting problem this went on for over a year if not 2 years and the starter motor finally gave out we didn't think the starter was at fault as it always started and well after it had a new starter put in it by god was like a new car. he had nearly 300k on that car and he sold it for another one i told him keep it was a great car and still was going well when he got rid of it 

[jimtaxi]

Thanks for getting back what I failed to mention was that the AA guy also said that the alternator was most likely faulty from new but as they are Denso to get a correct replacement they are very expensive. I know its a long shot but my car had been into the main dealer every year to check bad starting what I failed to notice at the time but looking back at invoices they always gave the Battery a boost charge or replaced it. The only person who diagnosed correctly was the AA but he of course had came over this fault previously.The alternator had basically an intermittent fault which was never showing itself in garage testing. Only me changing it regardless of testing results fixed the issue. Cheers for now good luck.