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Prado 1KZ-TE Starting and Idling Problems

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  • Prado 1KZ-TE Starting and Idling Problems

    Hello everyone! I recently just joined the forum but have been reading posts since I acquired my 120 Prado. I’ve read all the posts that are relevant to my problem and have gone to the auto shop with the information and had repairs/inspections done accordingly but have had only negligible improvement.

    Here’s what’s wrong with my 120 (auto transmission):

    1. Engine turns but takes time to actually start. We’ve changed the fuel filter assembly & primer, the inlet air temp sensor, turbo sensor and crank position sensor. There have been improvements, but it still occurs intermittently. Sometimes it can go a whole day without problems, sometimes it acts up the entire day. There is a loud clicking sound coming from the engine when it turns too long. Have no idea what that is.

    2. Idle drops when the vehicle stopped, on drive with my foot on the brake, but only when the ac is on. It gets worse when when I turn the steering wheel, sometimes when I’m parking the engine actually dies due to the idle dropping so low. But switch the ac off and it idles fine.

    Mechanics have ruled out the fuel pump, injectors and heater plugs. Those have been inspected and everything is in good working order. We’ve also inspected the spill valve with a multimeter and the ohm reading is within spec.

    We are all dumbfounded, plugging in the diagnostic tool shows no error code. I desperately need your help guys!
    jsbautista08
    Lurker
    Last edited by jsbautista08; 27-11-2018, 06:21 PM.

  • #2
    When you say replaced fuel pump, is that the injector pump on the engine? I recall spill valves testing OK but playing up when hot, replacing it fixed the problem. Second hand one somewhere or borrow one to sub the original?
    Cheers
    Steve

    Comment


    • #3
      My apologies, I meant to say fuel filter. I should edit that

      Comment


      • #4
        Rule out an air leak in the fuel line somewhere with a short length of clear hose between the fuel filter and the injector pump. Grab a couple of 3/8" barb fittings and make one of these up.


        Click image for larger version

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        Bleed the fuel line after fitting it and when the engine's running there should be barely any bubbles.
        Silver '04 KZJ120~Manual~GXL~Dobinson/Kings lift~Custom valved Ironmans~Detroit Locker~Endless Air~X9 Superwinch~Madman EMS1~TJM Dual Battery~Rhino Roof Tray~120W solar panel~Foxwing awning~Bushskinz UVP~Long Ranger water tank~Bushman fridge~Steinbauer P-Box~Beaudesert 2 3/4"~Airtec Snorkel~TJM Sliders~Prico Boost Gauge~BFG-KO2s~TPMS~GME TX3420~Front and Rear Cameras~Ultimate Camper hanging off the back!

        Comment


        • #5
          adrian5800
          Advanced Member
          adrian5800, that sounds like something I should do next. Will post back if that solves it.

          t303
          Senior Member
          t303, might be tough as that particular part is only sold here with a brand new pump. I’m gonna try to source out a used one and see.

          Thanks for both both your recommendations, any more ideas are most welcome!

          Cheers!

          Comment


          • #6
            adrian5800
            Advanced Member
            adrian5800 , we did the leak test and everything seems fine. Funny thing though, just by accident we accidentally forgot to reconnect the hose that goes from the MAP sensor to MAP filter and all of a sudden the Prado was starting fine! Connected the hose back to filter and the starting problem came back almost instantly. I can’t for the life of me figure out how to proceed.

            We cleaned the filter and hoses with carb cleaner and there’s some improvement. We’re still observing it, will post back a report.

            Any other suggestions?

            Comment


            • #7
              Replace the Map Filter and chuck a scan tool on and see the MAP sensor is reading properly.

              Comment


              • #8
                Originally posted by ejukated View Post
                Replace the Map Filter and chuck a scan tool on and see the MAP sensor is reading properly.
                This is definitely doable. What should the reading on the scan tool be? I've no idea what the proper spec is.

                Comment


                • #9
                  Originally posted by jsbautista08 View Post

                  This is definitely doable. What should the reading on the scan tool be? I've no idea what the proper spec is.
                  around 100kpa with the engine not running but ignition on reds. as you drive you should see it register boost till about 10psi (170kPa abs) at full throttle.

                  Comment


                  • #10
                    Hello guys, an update about my 120. So I took her to the official Denso calibration center after new year. They kept her for a week and now she’s perfect. So it turns out that the fuel pump internals were worn and out of spec. Spill Valve was fine so at least that wasn’t one of the things that had to be replaced. They took the pump apart, replaced what had to be replaced, stuck it into the calibration machine and that took a whole week. They also took down the injectors and replaced components that were worn. Total cost of repairs was just under $600.

                    Now everything is in spec and she’s running like a dream, dare I say, as good as the day she was purchased. Half turn and the engine starts, engine warms up in no time and fuel consumption is now much better at 15L/100km (used to be 25L/100km).

                    Comment


                    • #11
                      Originally posted by jsbautista08 View Post
                      Hello guys, an update about my 120. So I took her to the official Denso calibration center after new year. They kept her for a week and now she’s perfect. So it turns out that the fuel pump internals were worn and out of spec. Spill Valve was fine so at least that wasn’t one of the things that had to be replaced. They took the pump apart, replaced what had to be replaced, stuck it into the calibration machine and that took a whole week. They also took down the injectors and replaced components that were worn. Total cost of repairs was just under $600.

                      Now everything is in spec and she’s running like a dream, dare I say, as good as the day she was purchased. Half turn and the engine starts, engine warms up in no time and fuel consumption is now much better at 15L/100km (used to be 25L/100km).
                      Good to know! Thanks for posting back the solution. Wonder why the Injection Pump wore out

                      Comment


                      • #12
                        Originally posted by jsbautista08 View Post
                        Hello guys, an update about my 120. So I took her to the official Denso calibration center after new year. They kept her for a week and now she’s perfect. So it turns out that the fuel pump internals were worn and out of spec. Spill Valve was fine so at least that wasn’t one of the things that had to be replaced. They took the pump apart, replaced what had to be replaced, stuck it into the calibration machine and that took a whole week. They also took down the injectors and replaced components that were worn. Total cost of repairs was just under $600.

                        Now everything is in spec and she’s running like a dream, dare I say, as good as the day she was purchased. Half turn and the engine starts, engine warms up in no time and fuel consumption is now much better at 15L/100km (used to be 25L/100km).
                        Did they say if it was the timing control valve?
                        Silver '04 KZJ120~Manual~GXL~Dobinson/Kings lift~Custom valved Ironmans~Detroit Locker~Endless Air~X9 Superwinch~Madman EMS1~TJM Dual Battery~Rhino Roof Tray~120W solar panel~Foxwing awning~Bushskinz UVP~Long Ranger water tank~Bushman fridge~Steinbauer P-Box~Beaudesert 2 3/4"~Airtec Snorkel~TJM Sliders~Prico Boost Gauge~BFG-KO2s~TPMS~GME TX3420~Front and Rear Cameras~Ultimate Camper hanging off the back!

                        Comment

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