2.4TD Black Smoke Questions

[jon batson]

Hi from a Newbie.

Had my HiLux for about 6 years and no real problems in all that time. One Radiator about 3 years ago and timing belt about a year ago. Both I did. Car has done about 250000kms of which we've done about 80 to 100 thou. Car had a new engine fitted in Japan just prior to it coming over - but probably they still used the old pump and electronics???????

Anyway, had a blown tyre on the M11 two weeks ago at midnight on the M11 and after semi flattening the batteries changing the wheel while also trying to protect myself from juggernaughts passing at very high speed only a few feet away. In the end I had to have the AA get me home because the Alarm had failed off and they couldn't reset it.

Since then I have had to have the Alarm replaced and now I have black smoke from the exhaust under medium to heavy throttle or steep hills. Have taken it to two specialists and am told finally that it is the ECU because the ECU is not registering problems that they put on the car. Presumeably they disconnect a few sensors and expect the ECU to register the "failure" when they do the diagnostics. Both specialists said the EGR was not a problem.

Incedentally, the car starts fine, runs actually a bit better than before and top speed is definately higher. Tick-over is a bit lumpier. But the Auto Box still seems to change at the right times and the Turbo likewise seems to be operating as before - or even a little better. But fuel consumption is noticeably worse. However, the black smoke does seem to be gradually coming less now after maybe 100 miles or so and a few reasonably long runs - or maybe I'm just getting better at controlling it????

So - a couple of quick questions.

1. When the AA disconnected the batteries trying to reset the alarm, they presumeably also inadvertantly reset the Fuel ECU. Anyone know how long will the ECU take to re-learn the correct settings?
2. Is there anywhere I can get hold of a wiring diagram - I don't trust my various Haynes / Chiltern manuals?
3. Is the ECU a reasonably easy part to source in the UK - or is it rarer than rocking horse droppings and cost the national debt?
4. Is there anyway this could be connected to my AirCon not blowing cold air?
5. I have tried the redex "cure" - but it was in a full tank of fuel. No apparent difference - but is it worth repeating the dose??

Finally, I am a retired electronics engineer (not automotive I have to stress) so not a complete muppit - just feel like one is all. If it were not for the MOT being due in two days I'd leave it for a while to see what might happen "naturally" - but no choice - it won't pass an MOT like it is currently.

Clear moral in all this is don't turn your engine off and leave the lights on - nomatter what the excuse!!!!!!!!

Many thanks - any replies gratfully accepted - even rude and uncomplimentary ones - provided they're funny.

Oh! - and a 3.0 Litre ForeRunner backbox and resonator fit the Surf fine - you just have to fabricate an extension piece on the front to make up the 5 or 6 inches difference. That's only if you can't get hold of the correct one of course.

jon

[jon batson]

Good News - Found the Problem

On the basis that open ended threads are a pain I thought I'd finish this one with some good news.

After being told by two deisel specialists that they couln't read the diagnostics and that (in one case) this meant that the ECU was bad I can report a fix.

It's taken two weeks and £60 up me jumper - but in desperation and 4 hours looking through this site for as much background info as possible I got despirate and got my tools out.

First thing was to confirm that the diagnostic was working - short out the two pins and the ECU reported no problems - but still blowing black smoke as before. Disconnected all the various hoses and tubes one at a time- same result.

Next thing was to force some faults on the ECU by disconnecting the sensors that I could easily get to. The ECU reported the fault when in diagnostic mode - but still black smoke.

Took out the ECU and had a look inside. No obviously faulty components and not especially large scale integration with the use of mostly descrete components. Certainly a potential fix for an electronics expert with a diagram, the tools ('scope etc) and the background info.

Then I remembered the post asking for help on an immobiliser problem causing much the same symptoms as mine. Seems the red with black trace wire was a possible cause??

And hey presto I got very lucky - because I can see a red with black trace wire has been cut close to the ECU and the two ends spliced and taped as Thatcham dictate. I started to trace the alarm wiring and eventually confirmed it goes to the immobiliser.

Next step is to cut the immobiliser wiring out and rejoin (and solder and tape) the original red / black together as before.

Surf now starts and runs without the black smoke - and funnily enough the immobiliser still works as well. Maybe the wires I cut were the remains of the original Cat 1? Frankly I don't care overmuch as I'm up and running and the MOT now looks a distinct possibility.

Only other thing to add is that the ECU needs to have all three plugs removed to reset the alarm codes. The final time I did it I waited 15 minutes before reconnecting - but maybe only a few minutes (or even seconds?) might also work. But you must remove all three plugs - and this is easier if you remove the ECU from the bulkhead. It's under the passenger side kick panel by the way.

All's well that ends well I suppose - at least I didn't buy another ECU as was recommended.

Still got the Air Con to fix - but I've got 5 windows I can open so what the hell.

jon

[Koi]

Just another point on your MOT make sure its had a good run before you go to the garage, also may help just to do the EGR mod for the MOT.