1994 Toyota Hilux LN106 3L Excessive Smoke and Power Loss

[hiluxgalaxy]

Hey y'all! I just bought a 3L Hilux (no turbo), recently imported from Japan, two weeks ago, it's my first diesel and I already made some mistakes. I was driving out to Colorado and ran out of fuel on the Penna Pike (4 miles from the non-gouging station, because I didn't know there was no tank low light). The tow truck driver who came to bring me diesel convinced me to spray ether into the engine instead of bleeding the air, and I was naive/stupid enough to allow it (I'm still kicking myself). Before this, there was some black smoke coming out when accelerating hard, and sometimes when trying to maintain highway speeds (60-70 MPH) in 4th/5th gear. After, I sometimes have huge puffs of black smoke on cold start, when shifting into first. Driving through Iowa I was filling up at Casey's and could only maintain about 55 MPH, and I had added in LiquiMoly in Chicago. After filling up at a Shell, I was suddenly able to maintain 70 MPH, but that only lasted about 200 miles, and I haven't been able to since. Not sure if Shell fuel actually correlates with better performance, or that was just a fluke, because I haven't been able to recreate the effect. I'm also in Colorado now, so I'm not sure how much elevation has to do with it. Driving on the highway yesterday I lost even more power. If I started up a hill in third gear at ~40MPH, I couldn't accelerate at all and felt the engine was incredibly weak. There's also consistent smoke coming out (seems white, I can only see it at night by headlights behind me) when I'm at highway speeds.

The fuel filter was replaced about 1yr/8000 miles ago, the oil was changed two weeks/2000 miles ago (with 15W-40 synthetic, and a 90915-YZZD3 Toyota filter, which I found out is undersized), changed out the alternator, PS, AC belts as well. The gasket between the exhaust manifold and downpipe completely deteriorated, I ordered a replacement and am going to install when it arrives.

My current plan of action is to attempt to bleed the fuel lines, add an oil additive, drive a few hundred miles (is this a bad idea?), and get an oil change using Rotella T5 10W-30, and replace the filter with the correct, bigger 90915-40002 Toyota Filter.

Questions:
Strangely, during cold starts in the morning the engine seems to turn right over, but starting a warm engine (waiting for glow plugs), takes a few seconds of cranking. Any ideas why?

My understanding of bleeding the fuel lines:
1) Remove the fuel filter
2) drain it
3) refill it with diesel
4) reinstall it
5) Loosen all of the injectors one turn
6) start pressing on the hand pump on top of the fuel filter until fuel starts to come out at the injectors.
Are any of these steps incorrect? Am I missing anything?

Is there anything special I do to install the manifold gasket? Should I grease or oil it before installing?

What fuel/oil additives are recommended? Has anyone used FTC/FOC products or Fuel Ox and had success?

Does anyone know a trusty diesel mechanic in the Southwest (preferably near Denver) who has experience with these imported Toyota diesels? I want to get a compression test and find out if there are serious issues.

Has anyone purchased the gregory's or ellery's repair manuals? Thinking of buying one but they're gonna take a while to arrive... Has anyone used reliable-store's 1997 Hilux LN106 manual? Not sure if I should trust the site...

Any and all advice is welcome!!

I took a cold start video this morning but read that I can't share links and can't upload videos, so not sure if that's helpful or how to start it.

Cheers!

 

[AirheadNut]

Welcome and congrats on the Hilux purchase! I briefly had an LN106 and absolutely loved it. The first thing I would recommend is getting a PDF copy of the factory L-series diesel repair manual: 2L 3L 5L ENGINE RM520E copy.pdf - https://www.dropbox.com/s/2vzj7d20fdxu17q/2L%203L%205L%20ENGINE%20RM520E%20copy.pdf?dl=0

Elevation will certainly have a marked effect on the performance of a NA diesel, and at higher altitudes in places like Colorado I would expect a significant power loss and more smoke. Any kind of headwind will also cause a noticeable decrease in the top speed you can maintain. I doubt that one start on ether would cause engine damage, but it would still be worth giving your fuel system a once over and doing a compression test. I've had good results running straight Liquimoly Diesel Purge to clean injectors and the injection pump. Compression tests aren't difficult as long as you're competent turning a wrench.

When bleeding your fuel lines there's no need to remove the fuel filter first, just pump the primer on the filter housing until it goes hard. The primer pump is mostly there just to bring fuel up from the tank to fill a new filter or if you've run out of fuel. The best way to bleed the injector pump and injector lines is to start the engine, wrap a rag around the injector line fitting at the injector and slowly crack the fitting with the engine running. When fuel comes out consistently tighten it up and move on to the next one. However, since you've driven a decent distance since running out of fuel I would guess the system has self bled already.

How many km's has your Hilux done? It is fairly normal for them to smoke slightly at highway speeds, and if you can't see the smoke in the mirror in daylight I wouldn't be concerned about it. Even my VW TDI will make a haze visible when backlit by headlights.

You may need a certain number of posts to share a link or upload a video.

 

[hiluxgalaxy]

Thank you! That is an awesome link, thanks so much for sharing!

How often do you use the LiquiMoly? Is there anything I can do besides installing a turbo to improve performance at high altitudes? Should I be wary about taking it excessively high? I want to visit some friends in the mountains and I-70 peaks out at over 11,000 feet, not sure I'll make it up Vail Pass... An important note, it's the galaxy camper so it's heavier and air drag is an even bigger factor.

Cool, sounds simple enough, I'll give it a go!

I'm at about 149,000 km's. That's reassuring to hear, thanks.

 

[AirheadNut]

I've only ever done the LiquiMoly once on a given vehicle, I would think you could easily do 50k miles between cleanings. Unfortunately there really isn't much that can be done to improve high altitude power on a NA diesel, it is simply a function of how much oxygen the engine can get inside to burn the fuel. The big thing when climbing passes is to watch the tailpipe: if you start puffing lots of black smoke it's time to back off the throttle and possibly drop a gear. If you have manual locking hubs there's always the option of unlocking the hubs and putting it in low range to climb up over passes at 25mph; my uncle used to do that hauling 26k loads with a 1st gen Dodge Cummins. You could also plan backroads routes to avoid the higher speed traffic when climbing over the Rockies.

Very cool that you've got a Galaxy, apparently they're quite rare? Post some photos when you can, I'd love to see it! To be honest I'm surprised you were able to cruise at 70mph at all considering the extra weight and drag, your engine is likely pretty healthy.

If you do intend to add a turbo do some reading here on the forums, there are several people who have turbo'd 3L's and done lots of upgrades to 2L-TE's. There's a fair bit of work involved in keeping them running cool and reliably, but it is doable. It's best not to expect lots of power, I'd think of a turbo on a 3L as more of an altitude compensator. Something in the 8-12psi range, intercooled, would be about right.

 

[John in Utah]

Sounds like air is still getting into the fuel. Check the plastic water drain under the fuel filter, the oring deteriorates over time and can let air in without leaking a noticeable amount of fuel.

Also possible you just aren’t used to how brutally slow the 3L Hilux is. I cant even imagine how bad it is with a camper grafted to the back.

 

[hiluxgalaxy]

I've only ever done the LiquiMoly once on a given vehicle, I would think you could easily do 50k miles between cleanings. Unfortunately there really isn't much that can be done to improve high altitude power on a NA diesel, it is simply a function of how much oxygen the engine can get inside to burn the fuel. The big thing when climbing passes is to watch the tailpipe: if you start puffing lots of black smoke it's time to back off the throttle and possibly drop a gear. If you have manual locking hubs there's always the option of unlocking the hubs and putting it in low range to climb up over passes at 25mph; my uncle used to do that hauling 26k loads with a 1st gen Dodge Cummins. You could also plan backroads routes to avoid the higher speed traffic when climbing over the Rockies.

Very cool that you've got a Galaxy, apparently they're quite rare? Post some photos when you can, I'd love to see it! To be honest I'm surprised you were able to cruise at 70mph at all considering the extra weight and drag, your engine is likely pretty healthy.

If you do intend to add a turbo do some reading here on the forums, there are several people who have turbo'd 3L's and done lots of upgrades to 2L-TE's. There's a fair bit of work involved in keeping them running cool and reliably, but it is doable. It's best not to expect lots of power, I'd think of a turbo on a 3L as more of an altitude compensator. Something in the 8-12psi range, intercooled, would be about right.

I looked at the backroad route that I want to go and it has an aggressive climb to 11,500 feet too, should be an interesting ride! Hopefully I won't need to drop into the low range but that's great to know, I was always under the impression it was dangerous to engage 4wd without locking the hubs.

Yeah! I'm really glad I bought it, I was searching for a 4x4 van for a long time but this thing was a wayyy better buy. Here are some of the sale photos, I can post more over time as I take it to some cool places! I'm glad to hear that diagnosis, and looking forward to being near sea level so I can cruise like that once more.

I'm conflicted on the turbo, my trusty Russian mechanic told me an old saying that translates roughly to: "Don't touch the technology, and it won't screw you over", and told me to climb my mountain passes in first gear if I have to.

Sounds like air is still getting into the fuel. Check the plastic water drain under the fuel filter, the oring deteriorates over time and can let air in without leaking a noticeable amount of fuel.

Also possible you just aren’t used to how brutally slow the 3L Hilux is. I cant even imagine how bad it is with a camper grafted to the back.

Thanks for the tip! I just checked it and wasn't able to unscrew it at all, it's below freezing now (does that mean it might crack overnight if there is water in there? :/), going to try again in the morning. I ordered a new o-ring a few days ago but it hasn't arrived yet.

I got used to having big rigs flying past me and even tailgating me in some cases, at one point I was on a highway with traffic lights every mile and I managed to catch every red, accelerating each time was brutal. I noticed a substantial loss in power compared to how slow that was, I've already put ~4000 km's on it. What kind of cruising speeds to the pickup styles usually get?

 

[AirheadNut]

That's a gorgeous truck!

"Don't touch the technology, and it won't screw you over"

Wise words to go by, especially with an engine renowned for its simplicity and reliability like the 3L. As far as cruising speeds, when I drove mine from Vancouver, BC to Montana I was able to maintain around 110km/h on relatively flat ground (pushed it to 115 a couple of times along the coast), but hills and passes were generally a 4th gear proposition, probably 80-90km/h, sometimes slower. My brother had an LN107 that we took on a trip into Southern BC, loaded down with lots of gear and four people it could still cruise at 105km/h with the AC on but the hills were pretty tough. I remember grinding up over some in 3rd gear and having to keep backing off due to the black smoke pumping out the tailpipe.

That little plastic drain insert in the bottom of the fuel filter can be tough to remove. I've had best luck removing it with channel lock pliers wrapped in rags with the filter clamped in a vise.

 

[John in Utah]

I used to take mine back to CO a few times a year and it’s not too much of an issue. You won’t be going any slower than the big trucks up vail pass, just put the flashers on.

The turbo helps a lot, but there is a lot involved to add one properly.

 

[hiluxgalaxy]

Update - I'm in Copper now, the passes were brutal. Was barely able to maintain 40 km/h in 2nd gear, 3rd was completely unusable uphill. On the flat areas up here I'm only able to manage around 60 km/h and it's not very reliable. I tried using the low range and peaked out a little over 30 km/h and it didn't sound great, so I stuck to 2H.

Also possible you just aren’t used to how brutally slow the 3L Hilux is. I cant even imagine how bad it is with a camper grafted to the back.

So I guess you're right I wasn't yet prepared for how brutally slow it would be...

It idles very roughly, there's a kind of periodic jerking, which goes away a little bit if you rev it, and is present in first gear more so than second. I tried turning the throttle control under the steering wheel but it didn't seem to make a difference. I didn't drive with it turned because the owner manual said not to, but what's the more in-depth explanation of why that's bad to do? (Or is it actually fine in this situation?)

That little plastic drain insert in the bottom of the fuel filter can be tough to remove. I've had best luck removing it with channel lock pliers wrapped in rags with the filter clamped in a vise.

Sounds like a plan!

 

[John in Utah]

Update - I'm in Copper now, the passes were brutal. Was barely able to maintain 40 km/h in 2nd gear, 3rd was completely unusable uphill. On the flat areas up here I'm only able to manage around 60 km/h and it's not very reliable. I tried using the low range and peaked out a little over 30 km/h and it didn't sound great, so I stuck to 2H.

So I guess you're right I wasn't yet prepared for how brutally slow it would be...

It idles very roughly, there's a kind of periodic jerking, which goes away a little bit if you rev it, and is present in first gear more so than second. I tried turning the throttle control under the steering wheel but it didn't seem to make a difference. I didn't drive with it turned because the owner manual said not to, but what's the more in-depth explanation of why that's bad to do? (Or is it actually fine in this situation?)


Sounds like a plan!

The manual says not to because it’s not intended to be used as cruise control. If you’re just adjusting up a rough idle it’s fine.

L series Hilux go through a lot of engine mounts and that could be contributing to your rough idle. Check by engaging the ebrake and letting the clutch out a bit in 1st gear and reverse while a friend watches the motor. When my mounts were blown the engine would jump a good few inches.

But it sounds to me like air is still getting into the fuel

I will be out in Colorado over the holidays if you are still having problems I wouldn’t mind giving it a second set of eyes.

 

[Grease106]

Air filter ok?

 

[galaxytripping]

Hey y'all! I just bought a 3L Hilux (no turbo), recently imported from Japan, two weeks ago, it's my first diesel and I already made some mistakes. I was driving out to Colorado and ran out of fuel on the Penna Pike (4 miles from the non-gouging station, because I didn't know there was no tank low light). The tow truck driver who came to bring me diesel convinced me to spray ether into the engine instead of bleeding the air, and I was naive/stupid enough to allow it (I'm still kicking myself). Before this, there was some black smoke coming out when accelerating hard, and sometimes when trying to maintain highway speeds (60-70 MPH) in 4th/5th gear. After, I sometimes have huge puffs of black smoke on cold start, when shifting into first. Driving through Iowa I was filling up at Casey's and could only maintain about 55 MPH, and I had added in LiquiMoly in Chicago. After filling up at a Shell, I was suddenly able to maintain 70 MPH, but that only lasted about 200 miles, and I haven't been able to since. Not sure if Shell fuel actually correlates with better performance, or that was just a fluke, because I haven't been able to recreate the effect. I'm also in Colorado now, so I'm not sure how much elevation has to do with it. Driving on the highway yesterday I lost even more power. If I started up a hill in third gear at ~40MPH, I couldn't accelerate at all and felt the engine was incredibly weak. There's also consistent smoke coming out (seems white, I can only see it at night by headlights behind me) when I'm at highway speeds.

The fuel filter was replaced about 1yr/8000 miles ago, the oil was changed two weeks/2000 miles ago (with 15W-40 synthetic, and a 90915-YZZD3 Toyota filter, which I found out is undersized), changed out the alternator, PS, AC belts as well. The gasket between the exhaust manifold and downpipe completely deteriorated, I ordered a replacement and am going to install when it arrives.

My current plan of action is to attempt to bleed the fuel lines, add an oil additive, drive a few hundred miles (is this a bad idea?), and get an oil change using Rotella T5 10W-30, and replace the filter with the correct, bigger 90915-40002 Toyota Filter.

Questions:
Strangely, during cold starts in the morning the engine seems to turn right over, but starting a warm engine (waiting for glow plugs), takes a few seconds of cranking. Any ideas why?

My understanding of bleeding the fuel lines:
1) Remove the fuel filter
2) drain it
3) refill it with diesel
4) reinstall it
5) Loosen all of the injectors one turn
6) start pressing on the hand pump on top of the fuel filter until fuel starts to come out at the injectors.
Are any of these steps incorrect? Am I missing anything?

Is there anything special I do to install the manifold gasket? Should I grease or oil it before installing?

What fuel/oil additives are recommended? Has anyone used FTC/FOC products or Fuel Ox and had success?

Does anyone know a trusty diesel mechanic in the Southwest (preferably near Denver) who has experience with these imported Toyota diesels? I want to get a compression test and find out if there are serious issues.

Has anyone purchased the gregory's or ellery's repair manuals? Thinking of buying one but they're gonna take a while to arrive... Has anyone used reliable-store's 1997 Hilux LN106 manual? Not sure if I should trust the site...

Any and all advice is welcome!!

I took a cold start video this morning but read that I can't share links and can't upload videos, so not sure if that's helpful or how to start it.

Cheers!

Hey there! From one Galaxy owner to another, welcome to the club!

We’ve been traveling cross-country from the east coast and just made it to the high altitudes of New Mexico yesterday… it was a slow smokey drive. The smoke has been an issue on the uphills for us but it’s definitely been getting worse lately (hence why my recent Google searches led me here). We’re planning on popping into a diesel mechanic after the holiday to talk through options.

I’ll keep you posted on our course of action! Feel free to reach out, the best place would be on Instagram @galaxy.tripping. I’m in touch with a few other Galaxy owners on there who you could follow.

 

[hiluxgalaxy]

I've actually been in Utah for a few weeks now, changed the oil to rotella t5 10w-30 and lucas oil stabilizer with the right filter (90915-40002 instead of 90915-yzzd3), and I got better mileage, can use fifth gear and cruise around 100 km/h, and much smoother power shifting into 1st. I used Valvoline 15w-40 before, no oil additive. Not sure if it has more to do with the filter, the oil, or the stabilizer?

The engine mounts are great and the air filter is super clean.

Thanks for the responses guys! I'm about to follow you on insta!

 

[KZN130Alabama]

Just reading through this post so a bit late however when I bought my KZN130 (different model but still 3L Diesel 1KZTE) it felt way underpowered and had trouble with steep hills. I blocked the EGR line and did the fuel timing mod and it was a completely different truck. I'm cruising up the same hills and holding 90KMH easily. I don't know if that would help you but something to think about if your registered in a location that doesn't require inspections. These mods didn't throw a check light but I don't know if it would stand up to inspections or not.. Just FYI

 

[John in Utah]

Just reading through this post so a bit late however when I bought my KZN130 (different model but still 3L Diesel 1KZTE) it felt way underpowered and had trouble with steep hills. I blocked the EGR line and did the fuel timing mod and it was a completely different truck. I'm cruising up the same hills and holding 90KMH easily. I don't know if that would help you but something to think about if your registered in a location that doesn't require inspections. These mods didn't throw a check light but I don't know if it would stand up to inspections or not.. Just FYI

The 3L is a 2.8 liter NA motor. The 1kzte replaced it in a lot of applications but is an entirely different engine.

 

[KZN130Alabama]

The 3L is a 2.8 liter NA motor. The 1kzte replaced it in a lot of applications but is an entirely different engine.

Roger. Just noticed my error.

I thought he was talking about the 3.0.

 

[drewgold]

Came across this thread also searching to see if black smoke is 'normal' for these engines, I have the 5L but more or less the same engine.

I get a fair bit of black smoke as well, especially on hills and trying to accelerate in 5th gear. Seems to have gotten a bit worse with more mileage. (Just rolled over 100k kms)
I'm planning to have the timing checked at some point but altitude seems to play the biggest role, just not enough O2 in the mountains!

One thing I noticed, and something that I feel is often overlooked by owners of lower powered vehicles, is that it looks like @hiluxgalaxy is running heavy tires. Looks like you're on BF KO2's? E rated or C rated? What size? Those are great tires but extremely heavy which really impacts acceleration and uphill performance. In my truck, (Toyota Dyna) I can feel a definitive loss of power with my E-rated studded winter ties compared to my C-rated Wrangler Duratracs (Some of the lightest LT rated tires out there.) Rims also play a big role, looks like you're on steel wheels? Those are also boat anchors but may be tough to find aluminum wheels with the appropriate load rating. Everyone likes big rims but with each increase in diameter comes more weight. Just my two cents on wheels!

@galaxytripping Did you have have your truck looked at by a diesel mechanic?

 

[Rocky Mtn Hilux]

I own a '92 LN107 with the 3L, 2977 cc 4 N/A four banger. It cranks out a whopping 90 bhp, so it will never be accused of being overpowered. I've recorded some amazing gas mileage driving it, as much as 6.8L / 100 kms. on the highway. It produces better fuel mileage from winter diesel as opposed to summer diesel, the opposite of what it should do.

They are gutless on power at the best of times and belching out black smoke when accelerating is normal. I use a diesel fuel additive that raises cetane, lubricity, and allegedly fuel mileage every time I visit the pump. These old JDM engines do not like ULSD fuel, so a good quality additive is essential.

A properly running diesel engine should never belch out white smoke. That means its running way too rich.

If you neglect maintenance on these trucks, especially the engine and frequent oil changes, your wallet will curse the day you ever saw one. Mobil 1 high performance diesel oil is essential.



The 3L diesel is a high compression diesel that is an interference engine which usually sustains big damage if synchronization is lost. Disrupted synchronization allows the piston and valve to collide causing damage and very expensive repairs for the vehicle owner, especially old 3L motors and parts that are 3 deacdes old. Damage can occur to valves, pistons. or heads, and in some cases, completely ruin the engine. Most import (with higher compression engines) and most car and light truck diesel engines are interference.

I run 31.5 x 10.5 tires on 15" wheels and have a mild 2" lift on my Hilux.

Rocky Mtn Hilux

 

[hiluxgalaxy]

@drewgold no black smoke isn't normal or expected unless you're flooring it and the engine can't burn all the fuel you're dumping into it, or you're at high elevation and there isn't enough air to burn all the fuel. As rocky mtn hilux suggests, you have to use a fuel additive to make up for dry, poor quality diesel fuel (this is a great podcast if you want more info ).

I've tested out a ton of additives most formulations from stanadyne, royal purple, fppf, Lucas, power service, liquimoly but by far the best is hot shots secret, run a tank or two of diesel extreme and then run everyday diesel treat with every single tank. I use the higher dose. I drove cross country after rebuilding my injectors (new nozzles and springs) and felt very little performance improvement, but once I started using hot shots I could use fifth gear on the highway with no issues at all, and no black smoke unless I was really pushing the limit. I was getting 13-14 MPG before hot shots and am now getting 15-16, I even got 17 on one trip, and it seems to be slowly improving. I'm guessing it's giving new life to my injection pump and slowly cleaning it up.

I attached some pictures of the injectors, a brand new one, and two side by sides before and after cleaning. All that black gunk built up after 2000 miles on new nozzles using mediocre additives, I pulled them twice, and I just let them sit in hot shots diesel extreme and it basically wiped right off after that. My understanding is that when you're seeing black smoke, that same unburnt product is building up on your injectors and causing them to run worse. I was in a rush on one trip and was flooring it (I'm pushing a lot of weight, so not all that fast), and had a bit of blow by, and after that I felt I lost performance until I ran through a few gallons of fuel and my injectors got cleaned off again.

I went to a diesel mechanic and told him about some of my problems, asked him to tune my injection pump, and he told me about fuel issues and gave me a few bottles of FPPF total power and fuel power and told me they should take care of it. I thought he was blowing me off because he didn't want to deal with me. Ends up he was totally right, he just gave me a product that wasn't good enough. For the mountains, if you plan on staying in them, you might be able to tune a bit to get a better fuel to air ratio, but I don't know much about that.

Seriously, go buy some hot shots secret diesel extreme and EDT, it'll probably save you so much money and pain in the long run! I really wish I knew to use it as soon as I bought the truck, I would have saved hundreds of dollars on fuel and hundreds on parts and diagnostics fees, not to mention my time pulling things apart (although that was fun).

One thing I noticed, and something that I feel is often overlooked by owners of lower powered vehicles, is that it looks like @hiluxgalaxy is running heavy tires. Looks like you're on BF KO2's? E rated or C rated? What size?

They're 30x9.5R15LT 104S load range c up front, never taken them off because they were basically new when I bought it.

Also @galaxytripping recently turbo'd their engine and love it, said it's night and day, so yeah they've been to their fair share of diesel mechanics. Follow them on Instagram, Galaxy.overland, they're way more responsive there.

Tldr: use hot shots secret fuel additives

 

[Rocky Mtn Hilux]

Summary of Benefits of Using Xp3 Diesel Winter Xtreme:

• Decreases Cloud Point and Cold Filter Pour Point
• Improves fuel flow in extreme cold temperatures
• Inhibits wax crystals from growing together and plugging filters
• Extends engine life
• Reduces maintenance costs
• Decreases down time
• Cleans and maintains fuel injectors
• Is an effective biocide
• Increases power and performance
• Reduces toxic emissions
• Decreases DEF consumption
• Extends life of EGR/DPF/SCR systems
• Disperses water in fuel
• Improves lubricity
• Reduces fuel consumption
• Provides up to an additional 35 degrees of pour point protection to the pour point of the fuel being used

I have used Xp3 in all of my diesel engines for many years now. I just ordered some more. My last bottle lasted me well over 3 years. Another great thing about is it does not have any kind of shelf life problems. Keep it out of sunlight and it will last for years.


Rocky Mtn Hilux