Toyota Hilux D4-D 2KD-FTV engine rev problem

[aftab87]

Assalamaleikum, I work at a garage here in Kenya. Still learning stuff. Hope someone helps me on this so i can impress the boss. We have a Toyota Hilux D4-D 2KD engine. The problem is that when it reaches 3000 r.p.m, the check engine light turns on, the car does not rev anymore and there is a knocking sound from the engine. The car starts perfectly but as soon as it reaches 3000 r.p.m this problem occurs. The owner of the car went for diagnosis and it pointed to a faulty supply pump. we tried another supply pump but still no luck. Recently we changed the injectors but the problem still remains. Please guide me what else i can check. We have also changed the diesel filter and oil filter. I am aware i have to input the compensation codes on the injectors into the E.C.U but i think the problem is somewhere else. Thanx

[ShahSawaar]

Problaly a VIRUS in the car Computer

~

Naah, Lets just wait for experts' Opinion :d

[Charged]

Remove the Mass Air Flow sensor socket and run the engine and see if that makes any difference. If it does then change your MAF sensor sensor

And do not for get to check MAP (manifold air pressure) sensor as well.

[aftab87]

Thanx @ Charged. There is no Mass Airflow sensor in this car. And we did change the map sensor but the problem still remains. Today i tried connecting it to Launch X-431 diagnosis machine. It gave me two fault codes. 1 was mass airflow sensor and the other it said FUel System Leakage. I have checked fuel system but there is no problem there aswell. This car is giving a big headache. What else can the problem be. Its a Toyota Hilux D4-d 2kd-ftv engine model year 2007. I also wonder why it doesnt have mass airflow sensor. But it does have a vacuum sensor and i did change it. I also tried another fuel rail solenoid but no solution. Can someone give me the service manual for this car?

[Proverbial_Slang]

Check all the sensors. Seems like a sensor-related issue to me. There could be fuel pressure loss in the fuel system due to number of reasons. Check that carefully. Try the knock sensor too. Does the engine idle smoothly? does it perform normally until 3K RPM? Check the exhaust system as well.

[faisi001]

the problem is with the fuel pressure and for some reason ur fuel pressure is dropping...i had a similar problem and no one could trace the fault for days..
map sensor seems fine to me and the symptoms u said are truly from fuel pressure loss
first u should try checking the fuel rail which holds up the pressurized fuel from pump to the injectors and check if its not clogged
secondly im not sure if the pump is mechnical like conventional diesels or electrical if its electrical then try giving it a separate supply from the battery some times in electric pump the supply from the relay or the ecu signal is weak which drops the current to the pump and u get the same effects
thirdly check the fuel lines from the tank if they could be clogged and please fill the fuel tank to max first....
fourth take a bottle of diesel and put a pipe in it and feed it to the fuel pump directly and then start the car and check if that helps im sure 100% u might trace the fault if still it doesnt help then change the fuel maybe the fuel is accidentally mixed with another fuel...
please do inform us with the remedy which helped ur case
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[KKNIAZI]

Assuming your air intake and vacuum sensor as well as fuel pump, seals and injectors are OK, the only thing left is, some of them are already mentioned above.

1) Check the Vacuum pump (most likely caused)
2) Fuel pressure sensor
3) Check the lines to common rail if they are not clogged
4) Check common rail itself for pressure tightness/integrity

Please give us a feedback, whatever is the cause, and as you know start the engine after doing a reset of ECU by taking the negative terminal off for 3-4 minutes.

Sorry forgot to mention, when the check engine lights comes up, the ECU automatically limits the revs to less then 3K (????) and this is why you cannot rev it up anymore.

Cheers,
Kaleem

[aftab87]

I will try all your solutions tomorrow and i'll post detailed results. Thank you buddies. You are helping me alot. Allah bless you

[aftab87]

Thank you all very much...i will try everything you have said tomorrow and post all the detailed results. Allah bless you.

[rajadadevil]

it seems like fuel pump problem check that!
good luck!

[jz]

Assalamaleikum, I work at a garage here in Kenya. Still learning stuff. Hope someone helps me on this so i can impress the boss. We have a Toyota Hilux D4-D 2KD engine. The problem is that when it reaches 3000 r.p.m, the check engine light turns on, the car does not rev anymore and there is a knocking sound from the engine. The car starts perfectly but as soon as it reaches 3000 r.p.m this problem occurs. The owner of the car went for diagnosis and it pointed to a faulty supply pump. we tried another supply pump but still no luck. Recently we changed the injectors but the problem still remains. Please guide me what else i can check. We have also changed the diesel filter and oil filter. I am aware i have to input the compensation codes on the injectors into the E.C.U but i think the problem is somewhere else. Thanx

did u get IT check done?im sure u know about it,it will give out resutls telling if problem is with electrical system,i had an almost smiliar problem with my car,cut off which was supposed to be @ 6.5k came at 4k with constant back firing,n v v rich fuel,

later it was found out it was due to the ecu,ecu had lost its settings,i had to reset the ecu after that it worked fine n i got the it check to double check it

[jz]

ps
i also did check the fuel pump,fuel filter n injectors,they were all perfectly fine

[Xulfiqar]

your problem is with your MAF - and also with intake ducting including the intercooler - it must be clogged with gunk.. I had this kind of problem once - and it was solved with a new MAF - The fuel pump grounding switch on a MAF toyota is always in the MAF itself - hence the fault code.. - (Some big workshop in Karachi had advised to change injectors) lol

The other common rail problem but usually associated with Benz is the FPR becomes weak..

[KKNIAZI]

your problem is with your MAF - and also with intake ducting including the intercooler - it must be clogged with gunk.. I had this kind of problem once - and it was solved with a new MAF - The fuel pump grounding switch on a MAF toyota is always in the MAF itself - hence the fault code.. - (Some big workshop in Karachi had advised to change injectors) lol

The other common rail problem but usually associated with Benz is the FPR becomes weak..

I am not sure many engines will have MAP as well as MAF sensors working in tandem, certainly not TOYOs and is this engine intercooled?

If it is yeah you are absolutely right to check the muck and clear it out.

Since its Kenya, likelihood of bad fuel is another thing which one should worry about.

Cheers,
Kaleem

[aftab87]

I have ordered a new supply pump. If it works i'll post the result. And this hilux doesnt have an intercooler. I think only the 1kd engine has intercooler

[aftab87]

We managed to solve the problem. The supply pump was not the problem. There is something called a "Pressure Limiter". Turns out it was faulty, we changed it and the car runs perfectly normal. Thank You all for your suggestions, it really helped. I want to attach a pdf file, it has diagrams for Supply pump, Common Rail and Injectors. It helped me solve the problem. This forum only supports picture formats. If you guys would like to have it then pls tell me how to upload the file. I also tried renaming the pdf to jpg but it doesnt work

[Xulfiqar]

If you see my post - I wrote the FPR - becomes weak (usually a benz issue) but it can happen with any make too.

The FPR is fuel pressure regulator (aka fuel pressure limiter) in a Toyota :D.. Nice to know its fixed.

[hash4u]

are 2kd ob2?
if so, wats the use of having ob2 if it cannot help pin point the exact problem area

[Xulfiqar]

just the simple fact that Toyota are a cheap company and dont think that OBD error codes should be simple enough

[faadmemood]

So you impressed your boss?