dhopkins

I had the "death rattle" in my D4D until I blanked of the exhaust recyle pipe to the ERG valve. No more rattle!! Seems the rattle might be caused by the exhaust gases when the engine is cold? Also, fuel ecocnomy has imporved and seems to have more torque ie I can get up hills in 5th gear that previously had to be in 4th.

My Hilux 2005 D4D has done about 150ks and has been a great vehicle..no problems and good fuel economy. After reading about others and thier problems I have just finished installing the aluminium seals on the injectors and also putting a blanking plate to stop the exhaust bypass to the ERG valve. My first observation was that the original copper injectors seals were in excellent condition with no leakage. So it seems that the reported problem with leaking may be related to the injector clamps losing tension?? Having installed the new seals and all new gaskets and seals for the tappet cover I went for a test drive. I could feel better engine performance straight away and no death rattle!! To top it off I estmated fuel economy improved by 3 to 5 %. Having done about 1,000 km I also noticed that the oil is super clean...no diesel particles!! So, I am starting to wonder whehter the problems with blocked oil intake may also be related to the carbon coming into the engine via the ERG system. My suggestion is that if your D4D is running OK do not bother changing the injector seals, but first blank of the ehxaust bypass and see how it goes. While I am not sure whether there will be long term problems I welcome any feedback on this.