Chasing my tail!

[Kleb]

Hi everyone, I am brand new to this forum and have a problem with my 2009 D40 STX. It has 110k on the clock and has always had services up to date. Has never done any serious off road work.

The problem is it seem to 'misfire'. I have read a heap of forums on here looking for answers but still have come up with nothing. There is no problem with it starting cold or hot.

It goes like this, get in the car start it, drive out the driveway in 1st revs going from 1000rpm to 2000rpm 'hiccup' 'hiccup' for half a second, change gear into second 'hiccup' with a larger than normal black smoke cloud. Continue driving without a problem for a kilometre or so stop engine, to fuel up etc. Get back in start it take of and same deal. It wont just do it in 1st and 2nd will occasionally do it in any gear. Once it recovers from its little dummy spit it will drive and rev fine.

I have changed a few things but still nothing.

 

[Kleb]

By the way is a TD.
So far I have:

- Replaced the fuel filter with a genuine unit
- Replaced the MAF sensor
- Dropped the tank drained and cleaned it, fairly clean anyway.
- Flushed both the fuel pickup and return lines, bit of crap came out not much.
- Trimmed a small amount of the end of the hoses on the fuel filter as they seemed to have slight cracks starting nothing too bad.
-No check engine light, ran scan anyway no DTCs
-Disconnected ERG just in case it was coming on randomly, no change
-Ran a real time log of engine data rail pressure stays constant and directly increases with revs.

Maybe there is some other sensor somewhere playing up. Just don't know where to start, seem to be going around in circles! Doing my head in!

 

[puca]

we had a similar issue with my sons 2007 d40 it was the fuel injectors they were buggered he didn't have the coin to change them and this it what the mechanic said caused the timing chain to break it was over fueling and causing a hydraulic effect on the motor don't muck around with it get it looked at

 

[Kleb]

Is there any way of knowing for sure I have faulty injectors? Just want to be certain because I know they are not cheap. Funny thing too is that the hiccup won't happen every time it's driven it may go 1 week without doing it. Then boom it does it.

 

[Old.Tony]

I'd wonder if there was a problem with:

* The turbocharger actuator vacuum lines. Given the age of the vehicle, there's a chance that the vacuum hoses connecting between the actuator (gold round thing on top of the turbo) and the vacuum pump (down on the side of the motor near the oil filter) are hardened, loose, split or cracked. Check them very carefully, we had one person here check theirs thoroughly and couldn't find a problem, but when they tried to remove them, they found the issue. This is what I'd put my money on.

* The injector harness - debris in the connectors. Has the engine been pressure-washed?

 

[Kleb]

Tony
I have just checked the vacuum lines they didn't look too bad. Small signs of deterioration on the outer layer but not enough to wear though I thought. I trimmed the end off the line going to the actuator on the turbo anyway just to be sure.

And yes the engine has been pressure washed but I wasn't stupid with it, I kept what I thought was a safe distance. I didn't point it directly and any plug and just go for it. All connections seem to be air tight and waterproof. I disconnected all 4 plugs on the injectors and a bunch of other plugs and gently blew them out with compressed air the gave them a small hit of CRC 2.26 (the electrical stuff). Had the negative terminal on battery disconnected the whole time.

There is also three other wiring harnesses I found, driving lights, CB radio and a low voltage plug wired into the tub. These worried me as they were installed previous to me purchasing the vehicle. So they got the chop. Maybe is was something to do them??

Its all back together running ok. The test will be tomorrow morning and the next week. Thanks for the pointers Tony much appreciated. I will keep you updated.

 

[user 10312]

Always do one thing at a time that way you know what fixed it

Seriously tho, sounds like an injector problem. Especially if its more like a spark engine miss rather than a surge. Sounds like your onto it tho. The fact you had no fault codes, could of been just a poor connection on the injector terminals. Your done the right thing and checked the simple things first.

 

[nathand22]

suction control valve, they seem to play up and have varying symptoms, when it played up on my last d40 it was a fluctuating idle but only when cold, but after driving it would go and not return until the car had been off overnight.
they have been known to cause many other issues from loss of power to stalling and fluctuating revs.

 

[nathand22]

for injectors check out Baileys, its the cheapest option and come with more warrnty then buying new from anyone else, also they will be in a set of four that match better then standard which allows the coding to be set in a way that will get you better performance.

have a look at this link,
http://baileys-diesel-group.mybigco...denso-common-rail-injectors-095000-6250-YD25/




--------------

 

[nathand22]

for injectors check out Baileys, its the cheapest option and come with more warrnty then buying new from anyone else, also they will be in a set of four that match better then standard which allows the coding to be set in a way that will get you better performance.

have a look at this link,
http://baileys-diesel-group.mybigco...denso-common-rail-injectors-095000-6250-YD25/




--------------

here is a link to a thread i started back in june it has a few more links and info in there, it also mentions the trade in policy Baileys have which will lower the cost even more.

http://www.navara.asia/showthread.php?t=22865






----------------

 

[Dion]

this it what the mechanic said caused the timing chain to break it was over fueling and causing a hydraulic effect on the motor don't muck around with it get it looked at

What?

 

[Kleb]

Hi guys thanks for the tips and the links.! If this problem ends up being the injectors I will keep them in mind.

Ok after all that stuffing around yesterday. No change! Started it up this morning no problem idles fine like always. Drove off down the road about 300m and (misfire/cut-out/hiccup) whatever you want to call it, for half a second kicks back in the does it again and kicks back in and runs fine. It done it once more during the day and then was fine for the rest of the day.

Same old bloody story!

I just want it sorted but don't want to take the risk of purchasing new injectors then going mad because they weren't the problem.

So what's left to point the finger at? Injectors, Fuel pump, Crank Angle Sensor, gearbox??

 

[nathand22]

Hi guys thanks for the tips and the links.! If this problem ends up being the injectors I will keep them in mind.

Ok after all that stuffing around yesterday. No change! Started it up this morning no problem idles fine like always. Drove off down the road about 300m and (misfire/cut-out/hiccup) whatever you want to call it, for half a second kicks back in the does it again and kicks back in and runs fine. It done it once more during the day and then was fine for the rest of the day.

Same old bloody story!

I just want it sorted but don't want to take the risk of purchasing new injectors then going mad because they weren't the problem.

So what's left to point the finger at? Injectors, Fuel pump, Crank Angle Sensor, gearbox??

As i said earlier i would look at the Suction control valve, from memory they are about $300 to replace and course all sorts of issues when they play up with all sorts of symptoms.

 

[Old.Tony]

I'm suspecting the SCV now as well.

One member here (Shaunus88, if I recall correctly) has reported that simply cleaning the SCV worked for him. You could try that too.

 

[Kleb]

I just removed the SCV. Dismantled it and cleaned it. The spool didn't look too bad minimal wear and all O-rings looked ok. Put it back together re-installed it. And nothing! Truck spluttered then just cranked forever. Bugger! Pulled it back off put 1.5v on terminals nothing 6v nothing the 12v and it sounded like it wanted to actuate but just wouldn't, the valve seems to be stuck in the closed position. What I am guessing is a solenoid type setup inside the little beast just can move the pin to open the valve.

Not sure exactly the role it plays inside the pump but guessing is lets diesel in when the pump needs it then shuts off when its got enough and just cycles as needed. Perhaps based on engine speed?

Anyway I need an SCV now! Does anyone know where I can get one over the weekend in the Hunter Valley/Newcastle region?

 

[nathand22]

nizbits would have one but you wont get it over the weekend. and i wouldnt put a second hand one in as you could just run into the same problem.
By the sounds of it the SCV was sticking all along and is prob most likely the issue

 

[Kleb]

Out with the old in with the new! Got my hands on a fresh SCV today for $325.

First start of the vehicle and it wouldn't rev! No turbo and about 2500rpm was max. Guessing it must have put itself in limp mode maybe. Turned it off and back on and all sweet again. Let her warm up a bit and took it for a test drive.

First thing I noticed was that the engine has become a lot quieter and smoother! I have not felt it this smooth since about 30 000kms ago!

I will give it a week or 2 and let you all know how I go!

Thanks NathanD22 and all who have helped so far.

 

[kernels]

Just for reference, the SCV is what the ECU/engine uses to control the rail pressure. A very very important part.

 

[Kleb]

Bugger! Drove it down the road this arvo. Turned it off. Was off for about 15mins then get back in and start it no problems. Drive off 1st.... 2nd and "limp mode I think" no power wouldn't rev. Pulled over turned off then back on.

Take off 1st---------2nd------____---__----- Black smoke then all good again. So was good from first to second then dead, good, dead good.Its like the engine completely cuts outs for half a second or so. Just done the same thing again about 20 minutes ago.

Disconnecting the battery and resetting the ECU sort of seems to help for a little while, then when it gets comfortable again it starts to play up.

So whats next? Im open to all ideas just a little sketchy on spending my money this time.

 

[sparra04]

tps maybe? (throttle position sensor)
just a guess
maybe in the pedal box?