2002 TD6 fueling problem - cutting out under load

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Invogue

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62
Location
Lancashire
I've got a 3.0 TD6 L322 2002 model and its got a fueling issue thats really starting to **** me off now.

Its always been a little bit of a slow starter (about 2-3 secs to fire) but never had any running issues until about two weeks ago other than an incident with a diesel tuning box when I first got it.

Its going into limp mode/reduced power under load at high revs, i.e over 3.5/4k in kickdown and it first started on the motorway but will do it on normal roads when accelerating out of a junction for example. I believe it has been superchipped as it goes quite well for a 2.5 ton lump.

Its been on three different diagnostic machines at 3 separate garages, the first diagnosed a fuel pressure regulator on the end of the common rail. £180 plus £25 to plug it in for 2 minutes.

No change, I then took it to a mates garage and he used his snap on diagnostics which was reporting problems on the low pressure side. He'd had a few BMW's and Range Rovers in that needed the inline pump under the sill changing, another £100, no different.

I then changed the fuel filter just to be sure it wasn't something daft like that, again no change.

After that it went to another independent (Land Ranger in Atherton, Manchester - very helpful guys) and they plugged it into their autologic machine. It was still stating a low fuel pressure problem and they suggested either the sensor on the fuel filter or the in tank fuel pump. The fuel filter sensor was ruled out, as when unplugged it still went into limp mode under acceleration.

Whilst plugged into their machine it was saying that injectors 3 and 4 were reading low (should be between -1/+1 but they were -2/+2) and the fuel input low pressure reading was reading low which again we assumed was the in tank pump. I've just swapped over the in tank pump which was a bit of a job, spliting the tank mechanism but it saved me £200 off the dealer price. Theres still no change and I'm now £400 down in total.

Does anyone think it will be the injectors causing the issue? It drives fine under normal conditions and will sit at 80-90mph all day no problems, its just when a surge is required, its going into limp mode. It resets once the ignition is cycled and drives fine otherwise, no starting issues to speak of.

I did come across the problem when I first got the car 6 months ago, I fitted the tunit plug in box from my old TD6 and these issues were there then, I took it off and there were no problems till two weeks ago.

Sorry for the long drawn out post but I just want to sort this problem once and for all. I will be trying my mates fuel filter sensor from his X5 this week so if that curses it I'll let you know. I've got a feeling it might be these injectors but the computers are all saying its on the low pressure side not the high pressure.
 
My mates got the code faults.

From memory the first diagnostics pointed directly to the fuel rail sensor

The second snap on machine gave three fault codes, One was the low pressure fuel supply, one was a glow plug fault which was ignored and the other I can't remember but it wasnt relevant.

The autologic machine (3rd attempt) gave low fuel pressure fault again which was thought to be either the fuel filter sensor or the in tank pump which was the only other compnent on the low pressure side not changed.

I've had a chat with a toyota technician who is another mate and he thinks that the injector values wouldn't be at fault and his advice was to get it to a main dealer. I'm contemplating it but just dont want to get hit for a £1000 bill.

Does anyone know of any other sensors which may cause these issues? I've heard of people changing the crank sensor whilst researching it but I'm not convinced that this would sort it.
 
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