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Toyota Auris 2.0 D-4D - Persistent engine problems -garage cannot trace it - tim-cumbria

I have power loss problems and poor fuel consumption. Initially, on cold mornings starting was difficult - as if the heater plugs were dead. Once started it seemed to run quite well. Consumption soon dropped from 50mpg to 46mpg. Then it developed very intermittent but significant power loss. Mileage is now 97000.

It hasn't been right since a short while after a service, which apparently included fuel, oil and air filter changes. My regular garage changed the heater plugs. Two were dead. It gave a minimal improvement to starting and once running it was just the same as before. It went for another service and I said it was still a problem. They couldn't find anything and suggested waiting for a fault code to occur. Then it fairly suddenly started producing smoke, had less power and it indicated a fault. The garage said it was the EGR valve and replaced it. The smoke stopped but it still lacked power and consumption was still poor - Based on very few miles since the EGR valve change, I get 45 or so mpg when I try very hard for economy, but I know it should do 55-60mpg when driven that way. I see as little as 20+mpg if I try to drive it moderately hard in town, but with the chronic performance it accelerates slowly. On a cooler morning it still has the starting problem. After the service the garage had said that the engine was quite dirty and suggested a Terraclean. They also suggested Japanese cars are not the best for Diesels. So I had it cleaned. Maybe it runs more smoothly, maybe I am imagining that it runs smoothly, but apart from that it is no better at all. It has been parked-up since I got back from the terraclean on Monday and I'm using the bike.

I have had the car for 50,000 miles and keep a close eye on consumption figures. I do 15,000 a year, journeys almost all over 10 miles with over half that commute on the open-road at 50mph+. Roughly half my mileage is on two 135 mile motorway runs at 70mph every other week, which is why the car's average speed shows as 43mph, quite high. Oil consumption has been roughly measured and is higher than I would like, but at about 7000 miles per litre I presume it is OK.

Someone I know in the trade says the garage has a decent reputation. I know quite a few happy customers and I have used them for 6 years.

I would be very grateful for ideas. I have thrown over £500 at the problem already and am reluctant to spend more without getting information on the cause.

Edited by tim-cumbria on 20/05/2015 at 09:23

Toyota Auris 2.0 D-4D - Persistent engine problems -garage cannot trace it - Railroad.
You don't say how old your car is but I am assuming it's a common rail diesel. Am I correct?
Diesel engines are oil burners. That's what diesel fuel is - oil.
Air is drawn and compressed to a ratio of about 18:1. Fuel is then injected in precise quantities onto the hot highly compressed air. This then vapourises and spontaneously ignites. The mess left behind is quite horrific, even if it might seem that the exhaust is clean.
If your car is fitted with a diesel particulate filter then this is designed to collect most of the particulate matter, which is then later dealt with by a process known as regeneration.
Some of the exhaust gas is recirculated back into the air intake known as EGR for the purpose of lowering NOx emissions. The side effect here is that eventually the air intake becomes restricted with thick carbon sludge build up. The EGR valve itself simply opens and closes. It does not have any other magic function.

Based on what I've just told you your problem could be anywhere along these lines.
Blocked or restricted air intake or DPF or exhaust.
Faulty or dirty mass air flow sensor.
Air leak in air intake system.
Worn or stuck turbo wastegate actuator.
Worn fuel injector nozzles.
Low fuel pressure
Low cylinder compression.
Toyota Auris 2.0 D-4D - Persistent engine problems -garage cannot trace it - Fernando P

The last post sets out a very helpful explanation from Railroad - well done!

Tim Cumbria, writes - "they also suggested Japanese cars are not the best for Diesels". This and the comments in your report, indicates that the people you are dealing with in your garage are out of their depth with your problem. You should consider having your vehicle checked by an independent diesel specialist in the circumstances.

Toyota Auris 2.0 D-4D - Persistent engine problems -garage cannot trace it - madf

Firstly, get them to clean the MAF sensor. As time goes by, the fine wire collects dirt and it richens up the mixture...which means you burn more fuel..

(This requires great care as it is DELICATE)

www.toyotaownersclub.com/forums/topic/132301-d4d-m.../

And if that fails ask again.

Toyota Auris 2.0 D-4D - Persistent engine problems -garage cannot trace it - Micky-BO

On this model theres a exhaust gas cooling solenoid control which needs to be checked out has it got its 12v supply & is being activated by the ecu. Theres also a egr valve with built in potentimeter (position sensor) the plug on the egr valve has 5 terminals 1x 12v feed & 1x 5v feed. The 5 wires on this plug go to the ecu corresponding pin no's. I'm just wondering what checks the garage done before fitting new egr valve Regards Micky-Bo