Diesel Fuel Injection System Help Desk

[terano]

The potentiometer on top of the pump may have a poor contact to the harness, or the potentiometer could be malfunctioning.

Ask them to recheck this as this controls transmission shifting.

Sir, i went back to Zexel for follow up on this problem

Its the TPS pala where the potentiometer is (tama ba?)

Tried to adjust it pero ganon pa rin problem ko. Everytime patayin makina and paandarain ulit,, ayaw ulit mag shift, have to go to the engine bay and rev the terrano manually before it will act normally

Then the mechanic disconnected the electrical connection to the TPS, then the Terrano shfter normally. I turned off the Terrano, then turned it on and the shifting went smoothly .The problem was gone.

The mechanic said m TPS should be replaced.

I have to look in Banawe , this TPS

I said baka di pa sira, baka sa adjustment pa rin. i remembered he said before he has a friend who has expertise in automatic transmission.

So i suggested we visit him for 2nd opinion

The automatic transmission guy then check m TPS. He kind of measure the voltage in each electrical wre of the the connector of the TPS. He concluded that the the TPS is malfunctioning, it gives voltage rating that is abnormal so he suggested i buy a surplus in banawe

M question sir, since it is shifting normall today even if the TPS was taken out, do i really need it , i mean do i have to buy and install it back

What if i do not? An harmful effects on my automatic transmission in the future?

Thanks sir for the replies

[Dieseldude]

I have a 1998 Mazda B2500 that has clocked more than 211,000 kms already. Mileage is quite high....

My first question is before I had my 210k+ PMS, I started to hear a kinda weird and loud rattling/clunking like sound in the engine bay. At first I thought it was the flexible so I went to the shop where I had it replaced with a brand new one. They said that my flexible is still good and no signs of wear and tear and they think the sound is coming from the engine. What is a flexible?

When I brought it to my trusted shop for PMS, I told it my trusted mechanic and he said that by the sound, it needs calibration. I just don't remember the part that he said that needs to be calibrated, but it sounds like "injection" something. He also added that the car will not stall but the longer it takes, the louder it would become. More 1k+ kms after, it's still there and yah, I think it's getting louder but the duration of the sound is the same, I guess. Injector problem maybe......

That sound appears 10 to 15 seconds every time I start the car, most especially when turning the aircon on and after that, I will not hear until the next start up. The sound is like a worn out or about to wear out flexible. There are times that it wouldn't make that sound. This could also be a sign of imminent engine bearing failure. Take an oil sample from your engine crankcase and check for presence of metal particles...

For my second query, at the bottom of the passenger side, I noticed that something is leaking since it is making this circle wet marking. At first I thought it was just water dripping from the bed but it left a stain and everyday that same parking spot, it has wet marking. I tried to smell it and it's has a mild gas smell. From the naked eye, I didn't see any leaks. It's oil if stain is black, and either diesel of water if stain is light....

The third inquiry is at an uphill, I could feel that it is somewhat having a hard time going up. I don't know if I am just used to the common rail engine but really, I have to rev up to more than 3000 rpm just for it to go up. On flat roads, once it gets its momentum, I don't have any problems with it. The only thing is once it gets to 80 kph, it takes a very long time to get to 100 kph and even longer time to get to 120 kph and once it reaches 120 kph, that's it, it couldn't go any faster. Engine is not developing enough horsepower: insufficient fuel to the engine due to external fuel leakage, faulty fuel injection system, blocked filters, of failing engine....

I have just replaced my fuel filter with an original one from Ford about 5,000+ kms ago and it has pump. Air filter, I haven't replaced it since but a lot of mechanics told me that it's still good and it doesn't need replacement yet. Air filter is very important. By the way, does your engine smoke much, what color?

I just wanna know what's your stand on my questions especially on the 1st and 2nd questions. Thanks! You now have them. Share your findings at this forum so that we can all learn...

[Dieseldude]

Sir, i went back to Zexel for follow up on this problem
Its the TPS pala where the potentiometer is (tama ba?) Tama..

Tried to adjust it pero ganon pa rin problem ko. Everytime patayin makina and paandarain ulit,, ayaw ulit mag shift, have to go to the engine bay and rev the terrano manually before it will act normally

Then the mechanic disconnected the electrical connection to the TPS, then the Terrano shfter normally. I turned off the Terrano, then turned it on and the shifting went smoothly .The problem was gone. This is not an acceptable fix as the true failure was not verified, and the problem could intermittently happen again. On the positve side, you can now use your Terrano..

The mechanic said m TPS should be replaced. Replace the TPS only if you have verified that it is faulty. This part is not cheap. Ask Zexel to check it again.

I have to look in Banawe , this TPS. I caution you on buying 2nd hand TPS as you may also be getting a faulty unit. Also, TPS have many configurations, different pin designations and resistances. You have to get the correct part number...

I said baka di pa sira, baka sa adjustment pa rin. Correct, verify mo ulit. i remembered he said before he has a friend who has expertise in automatic transmission.

So i suggested we visit him for 2nd opinion This is correct. It is possible the Zexel's pump/TPS repair was good, but you may have a faulty TPS harness.

The automatic transmission guy then check m TPS. He kind of measure the voltage in each electrical wire of the the connector of the TPS. He concluded that the the TPS is malfunctioning, it gives voltage rating that is abnormal so he suggested i buy a surplus in banawe. He can say this only if he has the voltage and resistance specs. Sana hindi trial and error...

M question sir, since it is shifting normally today even if the TPS was taken out, do i really need it , i mean do i have to buy and install it back. What if i do not? An harmful effects on my automatic transmission in the future? I really don't know. We have repaired a lot of these pumps/TPS, but have never experienced this type of problem. Anyway, here are my thoughts:
1) Ask Zexel to verify TPS for proper function and adjustment. When this is done, go to step 2
2) Have an electrician check the harness connections to the TPS. Problem will probably be solved now. If not, go to step 3,
3) Ask Zexel and your transmission specialist to work together in finding the problem.

Thanks sir for the replies. You're welcome. Please post your fix so that we can all learn.

[rna800]

Mileage is quite high.... Yup, it is kinda high. It had 3 overhauls already because the 2nd one was done by those knuckleheads in one of the shops in the province where it stalled and I didn't have any choice but to have it repaired there. Basing from their price, I think it was something like 35k, I was really wishy washy on the quality. When I got the car, I didn't see a single part that got replaced instead, it was all receipts plus mangoes, a very dirty rug and a filthy slipper underneath the seats. Guess what, in 9 months time it got overhauled again. I brought it to my trusted mechanic and thank God, it's already more than a year already and so far so good though their price is double. It was overhauled sometime in February 08 by the way.

What is a flexible? If you will look beneath the car, there is an abanico like part that cuts through the muffler tube. I think it's used only in diesel engines due to vibration. Here is the link from Mufflerland http://www.mufflerland.com.ph/Flexible.html

This could also be a sign of imminent engine bearing failure. Take an oil sample from your engine crankcase and check for presence of metal particles... I think my mechanic did that at my last PMS about 1k+ kms ago and he said that nothing was irregular with the oil.
It's oil if stain is black, and either diesel of water if stain is light.... I really don't know what is its exact color due to that it is on the ground already, but it looks black to me but not as black as an oil spill though. At first I thought it was water coming from the bed but I noticed that even if the weather is scorching, that area never gets dry.

Engine is not developing enough horsepower: insufficient fuel to the engine due to external fuel leakage, faulty fuel injection system, blocked filters, of failing engine.... What is the best solution for this and what kind of work that needs to be done?

By the way, does your engine smoke much, what color? Nope, my car is not a smoke belcher unless I downshift and make the engine growl especially at an uphill. The smoke is black but it would eventually disappear.

[Dieseldude]

Mileage is quite high.... Yup, it is kinda high. It had 3 overhauls already because the 2nd one was done by those knuckleheads in one of the shops in the province where it stalled and I didn't have any choice but to have it repaired there. Basing from their price, I think it was something like 35k, I was really wishy washy on the quality. When I got the car, I didn't see a single part that got replaced instead, it was all receipts plus mangoes, a very dirty rug and a filthy slipper underneath the seats. Guess what, in 9 months time it got overhauled again. I brought it to my trusted mechanic and thank God, it's already more than a year already and so far so good though their price is double. It was overhauled sometime in February 08 by the way. Oh i see....

What is a flexible? If you will look beneath the car, there is an abanico like part that cuts through the muffler tube. I think it's used only in diesel engines due to vibration. Here is the link from Mufflerland http://www.mufflerland.com.ph/Flexible.html Flexible exhaust pipe pala ito. Baka sumsayad sa chassis?

This could also be a sign of imminent engine bearing failure. Take an oil sample from your engine crankcase and check for presence of metal particles... I think my mechanic did that at my last PMS about 1k+ kms ago and he said that nothing was irregular with the oil. Ask for a 2nd opinion.

It's oil if stain is black, and either diesel of water if stain is light.... I really don't know what is its exact color due to that it is on the ground already, but it looks black to me but not as black as an oil spill though. At first I thought it was water coming from the bed but I noticed that even if the weather is scorching, that area never gets dry. You have to know what this stain is as this will validate if you have diesel fuel leakage. Park your car on clean concrete pavement...

Engine is not developing enough horsepower: insufficient fuel to the engine due to external fuel leakage, faulty fuel injection system, blocked filters, of failing engine.... What is the best solution for this and what kind of work that needs to be done? 1) Check your throttle cable. Pump throttle lever should touch the maximum speed stop when your accelerator pedal is floored. 2) Check EGR function. 3) Check for any fuel or air restrictions. 4) Calibrate diesel injection system.....

By the way, does your engine smoke much, what color? Nope, my car is not a smoke belcher unless I downshift and make the engine growl especially at an uphill. The smoke is black but it would eventually disappear. This seems normal...

[rna800]

Flexible exhaust pipe pala ito. Baka sumsayad sa chassis?When I brought it to Mufflerland, they showed it me that nothing is wrong with the flexible. They tried to bang the whole pipe just to check if it would make any sound, it didn't. They said that if it's broken, just a little movement and it would make a clunking or rattling sound. I didn't see that it is hitting the chassis either. That is why the came up with the conclusion that the sound is coming from the engine and not from the muffler nor the flexible and advised me to check it with my mechanic.

Ask for a 2nd opinion.
You have to know what this stain is as this will validate if you have diesel fuel leakage. Park your car on clean concrete pavement...
1) Check your throttle cable. Pump throttle lever should touch the maximum speed stop when your accelerator pedal is floored. 2) Check EGR function. 3) Check for any fuel or air restrictions. 4) Calibrate diesel injection system..... I have already called Central Diesel Clinic and I have talked with a certain Ramon? I already informed him about the problems and he said just bring it to the shop so they could check and advise me to go to their recommended shops. Though I have a trusted shop and mechanic, I just want a second opinion.

Thanks so much, Dieseldude for all your help!

By the way, have you encountered any problems in connection with the DDI with regards to Global Dmax? It was released sometime in 2007, I suppose and it has been out in the market for 2 years already. Mine is already 9 months and has clocked just above 18k kms and so far so good. I just wanna know if there are isolated cases with which some owners went there since they are having problem with theirs. Hopefully none (cross fingers).

[Dieseldude]

Ask for a 2nd opinion.
You have to know what this stain is as this will validate if you have diesel fuel leakage. Park your car on clean concrete pavement...
1) Check your throttle cable. Pump throttle lever should touch the maximum speed stop when your accelerator pedal is floored. 2) Check EGR function. 3) Check for any fuel or air restrictions. 4) Calibrate diesel injection system..... I have already called Central Diesel Clinic and I have talked with a certain Ramon? I already informed him about the problems and he said just bring it to the shop so they could check and advise me to go to their recommended shops. Though I have a trusted shop and mechanic, I just want a second opinion. Ramon works with me at Central Diesel. Your trusted mechanic should be able to perform steps 1, 2, & 3, as well as check your oil for metal contamination. Step 4 will be a last resort, and should be done by an authorized diesel workshop.

Thanks so much, Dieseldude for all your help! You are welcome...

By the way, have you encountered any problems in connection with the DDI with regards to Global Dmax? It was released sometime in 2007, I suppose and it has been out in the market for 2 years already. Mine is already 9 months and has clocked just above 18k kms and so far so good. I just wanna know if there are isolated cases with which some owners went there since they are having problem with theirs. Hopefully none (cross fingers). So far, I haven't seen any major problem/s on this vehicle. Good for you.

[lord]

When is the time to avail of calibrating service?

Can casa not be able to do this?
My unit is innova diesel MT 2005.

Thanks.

[Dieseldude]

When is the time to avail of calibrating service?

Can casa not be able to do this?
My unit is innova diesel MT 2005.

Thanks.

I haven't seen a recommended service schedule from Toyota for the Innova's high pressure supply pump.

Casa is not able to rebuild this pump. They job it out to authorized diesel workshops.

[lord]

I haven't seen a recommended service schedule from Toyota for the Innova's high pressure supply pump.

Casa is not able to rebuild this pump. They job it out to authorized diesel workshops.

My innova's supply pump had been replaced by casa 2 yrs ago. And lately, last march, the hard starting recurred. Casa cleaned my fuel tank, replaced my fuel filter and did 'reprogramming' of my unit's ECU.

If such thing will hapen again, will I need the services of companies like Betan to calibrate my supply pump?

In my last trip to baguio, I've observed that my unit is lacking in power maski magpatay pa ako ng aircon which is the opposite of before.

Please advise.