Replacing 07 D4D Turbo Diesel Engine with another Engine?

[07xcabD4D]

hey all i hav had my 07 xcab turbo diesel hilux for over 2 years now, has been a really good car apart from the one problem i have had when the engine is cold, it blows alot of black smoke and rattles for the first 5mins until it is warm. Sometimes when your accelerating over about 2500rpm it will cut out on engine fault.

I have taken it to 3 different places now which none of them have been able to work it out, at first i thought it would of been just a faulty injector or something simple, but injector specialists reckon when they test them they all seem to be fine and to replace 4 electronic injectors would cost around $3000 and they wouldnt be certain if the problem would be fixed, others have tryed various things thinking they hav fixed it then a few days later the same thing would happen.

Everything else with the car is good, so i am even willing to pay the money for an older or recond similar engine if possible,

If possible what engines would fit into the engine bay,wiring harness... and would the rest of the car be able to take an engine thats not designed for that drivetrain,gearbox etc..........??

Any feedback or ideas would be much appreciated

Thanks Matt

[Steven]

The Hilux uses a typical ladder chassis with plenty of room in the engine bay so engine options really aren't a problem.

The rattles are pretty normal, especially when cold so I wouldn't normally consider them a part of your problem.

By the sounds of it something is causing it to run rich. My theory would be that you have a heavily clogged intake. Carbon buildup in the Hilux intake is a common issue, some get it worse than others for no apparent reason, and sometimes the carbon can restrict the intake quite badly. With so much restriction in the intake, the engine would tend to run rich (hence the black smoke) and as the revs increase there wouldn't be enough airflow that it might trigger an error code/engine cut that some people experience when blocking the EGR valve (ironically, the biggest cause of carbon buildup within the intake).

Try removing the top half of the intake (intercooler, throttle body right down to the EGR valve above the lower intake manifold) and inspect it, cleaning it with throttle body cleaner if necessary.

[CONROD]

Hi 07xcabD4D, The ECU generally has 3 modes; Start,Normal and idle.Start normally pumps in more fuel until the engine has reached the correct temperature,normal injects the diesel in response to signals it recieves from various sensors such as revolution,speed, airflow, temp sensors etc,etc,and idle mode delivers just the required amount to keep it idleing.So what you are experiencing is something the engine needs to do although the noise can be a bit daunting.remember the (CRD) Common Rail Diesel has pump pressure in excess of 20,000 kpa,and unlike diesels of the old school, (CRD) engines are all electronically controlled and minute amount of fuel contaminants can cause a rebuild that would cost a fortune.To put your mind at ease visit a reputable diesel workshop and ask all the questions you need,

CHEERS MATE CONROD