1KZ-TE Injection or Fuel Pump issues/replacement

[MUMSRIG]

Hey there Trav,

I replied to your PM mate

Cheers

[travis.luke]

More a Question for MUMSRIG,
picked my 2003 1kz-te manual with 272,000 from the doctors today after a 2 day stint. i went in due to a cold start issue and a slight lack in power when towing jayco camper up hills also, and they found the glow plugs are needing an extra 10sec after light goes out before firing it up, then then fun begins....
its got a FMIC and d-tronic chip to go along with all her power and it weighs in at a hefty 31Kw at the wheels and a huge 119NmT
Yep i S--T you not!! so im told its the Injector pump and i may as well do the injectors too then the time to play with it for tuning and what not.
what gets me is she still goes hard and would like to know if you can feel the difference before and after and even more so towing.
cheers, trav

[BlakMoth]

That's terrible news Mumsrig. Hope you can get it sorted soon


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[Canaust]

At this point we are bitterly dissapointed with the results, considering all we really wanted was the Steinbauer fitted and tuned! I hope that Diesel Care to some sort of ammacable arrangement and there wont be a need to take this any further. I will keep you all informed of the outcome.

I hope you get some satisfaction.

I will stay clear of them

[MUMSRIG]

I'm sure a diesel shop will work it out

Well so far not so good.

I picked it up during the week, as a matter of fact it had been there 1x day shy of a full month.

On paper everything looked good. The dyno readings were pretty much on par with when we 1st had it dyno'd many moons ago when the original chip was installed. The figures he was giving me wrong, they were actually KW not HP, so it wasn't quite as bad as it seemed.

However..................... the day before i picked it up they called and stated that my starting battery had dropped 2x cells... Well that was another $240 and I took a new battery with me. I hired a car trailer and drove out to Tamworth with my old ute and towed it back behind MUMSRIG as the train wouldn't arrive until the end of the working day.

This is part of the three and a half page letter that I have sent to them:

Whilst I was withdrawing the money to pay the bill from the bank, Wayne called and stated that technician had somehow managed to break the headlight protectors (of which Diesel Care did replace, not the point though). Whilst I was fitting the battery I noticed that the Provent Oil Catch Can had been removed and re-installed incorrectly. The mounting bolts were different and the bracket spacers were missing, however a banjo bolt style fitting had been installed under one of the brackets. I called Wayne who then sent the technician across with the correct spacers but he was unable to find the original bolts and washers. He went back to the workshop and located some other bolts that were suitable. The Provent was also missing the plastic retainer to hold the ribbed mount together and I asked of it's whereabouts to Wayne, he said he would check and send it via the post once located. I also found a copper washer on the belly plate of the vehicle and am unsure of where this came from? I also enquired as to why one of the factory harness plugs to the pump was now damaged and held together with a cable tie, no satisfactory answer was provided. All of this was evident just whilst I was simply replacing the battery!

I then hoped into the vehicle to start it and noticed that the dash cam had been removed from its windscreen mount and the power cable was hanging down. Subsequently I found this in the glove box. Why would there possibly be a need to remove this?

When I was ready to depart I asked Wayne for the replaced components to be told that the injectors were reconditioned and not replaced with new ones as we were lead to believe in our discussions to date and also that the Injector Pump was exchange. At no point were we informed of this. I then explained to Wayne that West End Diesel could supply an exchange pump for $1765 inc and I had received a price through Toyota for a new pump at $1900 at trade price. I asked why your pump was so dear being exchanged?
I always drive with the headlights on and did so on the way back to Muswellbrook. It wasn't until i arrived home that I realised that the right headlight was not functioning. Upon further investigation I found that it was not getting any power. The vehicle is fitted with HID's, so I traced the power back and found both the Positive and the Negative leads to be disconnected from the HID module. I reconnected these and the light still did not activate. I looked further into it and tested some other connections only to find that the polarity had been reversed into the HID module from the battery. Once re-connected the correct way the light now works. Hopefully this hasn't damaged any of the circuitry in the module. Whilst checking all of this I also found a Diesel Care pen down beside the air box in amongst the wiring. I'm just glad it was daylight saving and I didn't have to drive in the dark on the way home.

Since picking the vehicle up from your store and paying the bill of $4218.50, I refilled it with fuel in Tamworth and began the drive back to Muswellbrook. Approx 20klm's out from Tamworth I called Wayne as it was blowing excessive diesel smoke out of the exhaust under load with the car trailer and Falcon ute on the back and the EGT's increased dramatically, exactly the same symtoms that I was complaining about when I bought it to you. After talking to Wayne on the phone I removed the fuse on the ChipIt Chip and drove the rest of the way home without it. The vehicle performed no different to how it did previously without the chip and I again called Wayne and informed him of this. I did attempt to increase the boost back to 15PSI to see if it would help with the ChipIt connected however I didn't have any allen keys with me to be able to undo the locking grub screw on the TurboSmart Tee. I also checked the ChipIt Chip to see what setting the jumper tab was on and found that one of the screws for the end plate was missing completely and that the chip had been set back to position one (which I would have done if it wasn't), but seriously, another thing albeit simple that I have found after picking the vehicle up!

Another point that I would like to make is that on the morning I dropped the vehicle off I stopped at the local car wash and washed and vacummed it. When I picked it up there was diesel soot all over the back end, obviously from running it on the dyno, it would have been a nice gesture to at least have cleaned this off for your valued customer.

I completed the drive home with the chip disconnected and then went on through to Newcastle and return the following day completing 411klm's before refuelling again which resulted in consumption figures of 17.52ltrs/100klms. I understand that I was towing, however that was only from Tamworth to Muswellbrook and the rest of the distance was without the added load. These fuel consumption figures are still well over what we were expecting to see especially after spending all that time and money in your branch. I will be performing further consumption tests but I can't see there being any massive improvement considering not even half of the journey was whilst towing.

At this point we are bitterly dissapointed with the results, considering all we really wanted was the Steinbauer fitted and tuned! I hope that Diesel Care to some sort of ammacable arrangement and there wont be a need to take this any further. I will keep you all informed of the outcome.

[scottkz]

Yeah 30 sounds a bit low maybe a bit of exaggeration ? From them
I like the 1kz power only time it lacks a bit is at hwy speed overtaking 4wding around town it's great
I'm sure a diesel shop will work it out

[MUMSRIG]

I'd be going striaght to the boost sensor on the side of the cooler they can be buggers of things run perfect but no power , it tells the ECU when it's on boost so it can put more fuel in

I know the D4D's have that issue as I've diagnosed and fixed them myself before, it doesn't feel underpowered like those. It's just a 1KZ that's never going to have the power of a D4D.

I still can't get past the fact that they have said it only has 30hp at the wheels.. Didn't drive like that at all, that's a third of what it should have!

[MUMSRIG]

Ok, things I would check, and I presume Diesel Care have checked all these before assuming the pump is cactus, was the lack of power/high fuel consumption/stalling occurring after the head replacement? Directly after? Sometime after?
Logical stuff first, camshaft timing, pump timing, check for any fault codes - crank position sensor, timing control in pump. Put a fuel vac/pressure gauge in the fuel line at the pump inlet and run under load and see if there is a large vacuum present (blocked lines, pick up in tank etc - fuel lines can break down and get a flap of rubber inside that will act like a one way valve especially at the barb on the filter). Inlet manifold pressure sensor blocked line, faulty sensor, check inlet boost pressure with another gauge under load, (low pressure can indicate fuel supply problem) stuck egr valve, turbo waste gate stuck or maladjusted, blocked exhaust system - check back pressure under load. Does it have a standard exhaust or aftermarket?

Keep you going for a while.

Good luck.

Stalling stopped after the head was fitted. Hunting wasn't as bad either after.

Turbo is brand new fron AXT Turbos (highflow).

Exhaust is a 3" mandrel bent system and I had it off and checked when I did the head and turbo.

Thing is, I didn't think it was that underpowered.. Just needed a bit more grunt for towing hence the reinstall of the chip. Personally, I thought it was chip related.

EGR is blanked off to.

Will wait to hear back from them and see what they say..

Thanks for your suggestions.

[scottkz]

I'd be going striaght to the boost sensor on the side of the cooler they can be buggers of things run perfect but no power , it tells the ECU when it's on boost so it can put more fuel in

[adrian5800]

Ok, things I would check, and I presume Diesel Care have checked all these before assuming the pump is cactus, was the lack of power/high fuel consumption/stalling occurring after the head replacement? Directly after? Sometime after?
Logical stuff first, camshaft timing, pump timing, check for any fault codes - crank position sensor, timing control in pump. Put a fuel vac/pressure gauge in the fuel line at the pump inlet and run under load and see if there is a large vacuum present (blocked lines, pick up in tank etc - fuel lines can break down and get a flap of rubber inside that will act like a one way valve especially at the barb on the filter). Inlet manifold pressure sensor blocked line, faulty sensor, check inlet boost pressure with another gauge under load, (low pressure can indicate fuel supply problem) stuck egr valve, turbo waste gate stuck or maladjusted, blocked exhaust system - check back pressure under load. Does it have a standard exhaust or aftermarket?

Keep you going for a while.

Good luck.

[MUMSRIG]

Called Diesel Care today, didn't get to talk to the Foreman as he was working on a vehicle on the dyno.. The secretary did how ever say that he would call me back this afternoon (didn't happen), then she said that they were still chasing power issues!! So I'm guessing the pump didn't solve the issues.?

MUMSRIG has been there for two weeks now

Looks like we are travelling to Bathurst in my old ute with the camper in tow

[MUMSRIG]

Had chip disconnected when I put the head on. All good, fuel economy of 17 to 18ltrs/100 didn't change.
Brand new K&N filter
Injectors were done before leaving Perth
Reinstalled chip in the quest for more power which I found but even running 15psi didn't ebate the fuel out the back. EGT's started getting up also, hence the trip to Diesel Care.
Now has new injectors and waiting to hear back from them to say the pump is fitted and everything is A OK!

[Chaser]

Has chip, new genuine air filter. Pumps new and i got it for 1900. haven't done injectors too lazy. Don't blow smoke without so with chip needs more boost hahaha!

[Anth120playdo]

Yep my pump was shagged at 200k. I haven't done injectors tho and its blowing shit loads of smoke out its bum when towing. I might get a set of injectors for it then. I had my pump done my tamworth too. Haven't gone up there and had the chip tuned to suit tho. How much fuel were you using mitch? I'm at high 13's low 14's now with all the fruit. Heading away with the camper for the long weekend and not looking forward to the fuel bill .

IMO

Common Things that cause smoke on 1kz:

Chips.
Blocked air filter.
Shagged injectors.
Fuel pump.

Rectification:

Loose chip. Drive & see if ok.
Replace air filter. Drive & see if ok.
Change injectors from a diesel specialist. Drive & see if ok.
Check change pump. Get a new fuel pump from Toyota just over $2000 here, ask rick_nz for a price. Change it & if your not sweet now, it wasn't a common cause.

[Chaser]

Yep my pump was shagged at 200k. I haven't done injectors tho and its blowing shit loads of smoke out its bum when towing. I might get a set of injectors for it then. I had my pump done my tamworth too. Haven't gone up there and had the chip tuned to suit tho. How much fuel were you using mitch? I'm at high 13's low 14's now with all the fruit. Heading away with the camper for the long weekend and not looking forward to the fuel bill .