2.2 D4D 2005 Toyota Verso blue/white smoke

[Tdub]

Hello.  I have a 2005 2.2 D4D Toyota Verso and have had a bunch of problems.  It started with the EGR clogging.  I went through the cleaning process and the first time I cleaned it there was lots of junk in the 4 rectangular intake holes and inside the valve. I vacuumed out intake and then pulled the valve apart and made sure it actuated properly by hooking Battery into it and it cycled back and forth fine.  I then put it back on car and it and the car ran ok for a bit.  Then a month later, I had the P0401 error come back on.  I pulled the EGR apart again and it wasn't very dirty.  After putting it back together again, the problems didn't go away.  My next action was to take it to a local mechanic (I'm in Italy) and he figured out the Diesel Particulate Filter was clogged--at this point I had never seen any white or blue smoke coming out of the car ever. 

The mechanic pulled off DPF and cleaned it at a car wash until water flowed through clearly.  It was by no means the professional EGR/ultrasonic cleaning operation I've seen on some of the videos but I don't have a clue where to find that here in Sicily.  Anyway, he put the DPF back on the car and I drove it away.  It ran fine for about 150 km, but then I got the P0401 error and the car went into limp mode.  I pulled the EGR off and there was lots of hard carbon soot (they looked like little black rocks) in the valve so it would not actuate.  When I cleaned that out and reset the ECU (via pulling off Battery terminal) the car ran normal again.  This clogging occurred at least 3 more times and I pulled over on the side of the highway to clean EGR each time and I was able to clear limp mode.

After about 200 km I started seeing lots of blue/white smoke that wasn't there before and is now a common occurrence.  It starts after the car has warmed up and randomly spews bluish/white smoke out the back of the car in a variety of driving conditions (on hills, on flats, at highway speed, at idle).  It seems like the car is stuck in DPF regeneration mode.  I pulled out the 5th injector (thank you other forum members) and cleaned it but that didn't solve anything.  Does the DPF control/monitoring operation in the car's ECU have to be reset after a cleaning?  I don't have a means for monitoring the car's operation in real time. Could it also be the differential pressure sensor sending false values?   The engine oil hasn't changed nor has the coolant level.  The turbo is spooling up properly and the car has plenty of power so I don't suspect bad head gasket or bad turbo.  

Also, being in Sicily, we don't have emissions tests.  Does anyone know the process for deleting the DPF and remapping the car's ECU?  Is it as simple as faking out the 5th injector so it won't inject and gutting the DPF?  Does anyone know if that would cause the car to go into limp mode? I appreciate any input you all can provide.  I know it sounds really hypocritical that I want to remove emissions controls so the smoke will go away but I also feel bad smoking out the locals as I drive through the small towns. 

[Tdub]

As an update. I just took off the electrical plug to the 5th inject and shorted a resistor across the terminals.  I drove the car around for 40 miles and didn't see any smoke and it did not throw a code.  I suspect the differential pressure sensor is giving false readings, but I might set up the injector so I can switch it on and off manually when the DPF needs a clean.  It's pathetic how bad this Toyota's emission control system operates.  

[kris poole]

On 2/28/2022 at 1:03 PM, Tdub said:

As an update. I just took off the electrical plug to the 5th inject and shorted a resistor across the terminals.  I drove the car around for 40 miles and didn't see any smoke and it did not throw a code.  I suspect the differential pressure sensor is giving false readings, but I might set up the injector so I can switch it on and off manually when the DPF needs a clean.  It's pathetic how bad this Toyota's emission control system operates.  

Hi I have a d4d 177bhp decat rav4.. I get the white with tint of blue smoke loads.. changed 4 top injectors fuel pump and primer. Cleaned egr.. don't get fault codes. But remap guy said it could be turbo or piston rings. Where is the 5th injector? Thx