hilux surf ln130 2lte black smoke rough startup

[TheBoomba0]

hey all, new to this forum but see lots of helpful threads. hoping somebody could point me in the right direction before I pawn this problem off to some other poor soul. long story short. like most 2-lte owners I'm tearing out my hair trying to figure out what is going on. not sure if the issues are related but I get immense white unburnt diesel and misfire at startup and when the truck is heated I get thick black puffs of smoke on acceleration. the computer reads fault codes 2 (boost pressure sensor) and code 5 (IP correctional resistors) and to rule out these issues. I just had the injectors rebuilt, new glow plugs (tested and working properly) just fitted a new CT20 turbo and removed my EGR system. have checked all of my vacuum lines and connections. brought the vehicle in to a mechanic and the IP resistors have the correct values and all seems to be working fine... I've replaced the fuel filter several times and it always seems to let its smog loose like free willy at the end of each day. oh and get about 300km per tank... used to get 400-450 getting extremely frustrated and would love if somebody had some feedback or solutions for me to try. thanks in advance, cheers
Travis
1990 2LTE 175k
cyl 1:460
cyl 2:420
cyl 3:380
cyl 4:420

 

[pappy]

Well, us gassers here are a very knowledgeable bunch, but when it comes to diesels, well .... There is a diesel forum here at MUD, and that's where this post has been moved. Good luck.

 

[GTSSportCoupe]

hey all, new to this forum but see lots of helpful threads. hoping somebody could point me in the right direction before I pawn this problem off to some other poor soul. long story short. like most 2-lte owners I'm tearing out my hair trying to figure out what is going on. not sure if the issues are related but I get immense white unburnt diesel and misfire at startup and when the truck is heated I get thick black puffs of smoke on acceleration. the computer reads fault codes 2 (boost pressure sensor) and code 5 (IP correctional resistors) and to rule out these issues. I just had the injectors rebuilt, new glow plugs (tested and working properly) just fitted a new CT20 turbo and removed my EGR system. have checked all of my vacuum lines and connections. brought the vehicle in to a mechanic and the IP resistors have the correct values and all seems to be working fine... I've replaced the fuel filter several times and it always seems to let its smog loose like free willy at the end of each day. oh and get about 300km per tank... used to get 400-450 getting extremely frustrated and would love if somebody had some feedback or solutions for me to try. thanks in advance, cheers
Travis
1990 2LTE 175k
cyl 1:460
cyl 2:420
cyl 3:380
cyl 4:420

I live in Victoria also and might be able to help you out over the holidays if you want to drop by my place on day. I know these motors pretty well. I also have an extra boost sensor you could try. Sounds like yours is reading maximum boost all the time based on all the smoke you are seeing and poor economy. This will mean high EGT's also, which can overheat and damage your motor, so be careful.

Some ideas off the top of my head:

- Some times the capacitors leak in the engine computer board and cause all sorts of grief. Maybe worth checking that?
- Have you carefully followed the boost line from the intake manifold to your boost sensor to make sure it's ok?
- I recommend disabling/disconnecting the emissions throttle in the throttle body (the one connected to the VSV). This will leave it open all the time and let the engine get more air at startup. This might solve your startup problem. Many of us have also completely removed the butterfly valves in the throttle body to give maximum air all the time, which really improves the motor in a number of ways including a clean startup.
- When the weather is freezing I often give my motor two glow cycles to get a clean start, as the factory glow time is not quite long enough.

 

[cruisedeisel]

GTS Knows these 2l-te very well. listen to him^^^^

 

[TheBoomba0]

I would much appreciate your time if I could pick your brain and try out your boost sensor. my holidays started at 5PM today so I'm free for most of the week! the hardest part for me seems to be finding answers to my questions and ive seen enough of your threads to know that you have a great understanding of what is going on with these things. that would be very very helpful to me!

 

[TheBoomba0]

I live in Victoria also and might be able to help you out over the holidays if you want to drop by my place on day. I know these motors pretty well. I also have an extra boost sensor you could try. Sounds like yours is reading maximum boost all the time based on all the smoke you are seeing and poor economy. This will mean high EGT's also, which can overheat and damage your motor, so be careful.

Some ideas off the top of my head:

- Some times the capacitors leak in the engine computer board and cause all sorts of grief. Maybe worth checking that?
- Have you carefully followed the boost line from the intake manifold to your boost sensor to make sure it's ok?
- I recommend disabling/disconnecting the emissions throttle in the throttle body (the one connected to the VSV). This will leave it open all the time and let the engine get more air at startup. This might solve your startup problem. Many of us have also completely removed the butterfly valves in the throttle body to give maximum air all the time, which really improves the motor in a number of ways including a clean startup.
- When the weather is freezing I often give my motor two glow cycles to get a clean start, as the factory glow time is not quite long enough.

also, thanks for the reply. talking in person cuts time in half but I am looking into removing the emissions throttle and butterflies. just simply don't have enough knowledge to jump into it and ive been slowly reading up on forums as I go to understand how it all works. was hoping to fix my overfuel/overboost problem before I tore out the valves to be safe and don't really know where to start tbh.. I have been double glowing her recently but not making all to much of a startup improvement. have checked the boost line up and down several times and cant notice any imperfections or oddities. cheers

 

[GTSSportCoupe]

also, thanks for the reply. talking in person cuts time in half but I am looking into removing the emissions throttle and butterflies. just simply don't have enough knowledge to jump into it and ive been slowly reading up on forums as I go to understand how it all works. was hoping to fix my overfuel/overboost problem before I tore out the valves to be safe and don't really know where to start tbh.. I have been double glowing her recently but not making all to much of a startup improvement. have checked the boost line up and down several times and cant notice any imperfections or oddities. cheers

Sounds good. I'm on holidays starting on the 23rd, but I have young kids, so it will be a bit tricky finding a block of time to meet. I'll be in touch by PM once I figure something out. Probably an evening will be the only option. I'm pretty sure we can figure things out with your motor pretty quick.

 

[TheBoomba0]

Sounds good. I'm on holidays starting on the 23rd, but I have young kids, so it will be a bit tricky finding a block of time to meet. I'll be in touch by PM once I figure something out. Probably an evening will be the only option. I'm pretty sure we can figure things out with your motor pretty quick.

great! an evening would work just fine for me. I sure hope that's the way it goes! appreciated. ill hear from you in the PM! cheers

 

[pnwhilux]

Hi there!
I know this thread is very old but did you two ever find a solution?

I just replaced the head on my ‘93 2lte Surf (big surprise, I know) and now I have white smoke on start up, very rough idle for the first minute, and then excessive black smoke when driving after that.

In the past month I have replaced the injectors, glow plugs, fuel rail, o-rings and seals in inj pump, head, gaskets, radiator, and thermostat.
If you guys have any advice I would really appreciate it.
Cheers