TD5 Driver Demand Faults

G'day all, time for an update.

With the ongoing issues not looking like being solved in the short term I started looking for another vehicle as my daily drive as the hire car costs started to add up so here is my new daily drive which I absolutely love.

http://www.aulro.com/afvb/european-m...1-110-g55.html

I rang a few companies in the UK & one of them really seemed on the ball, so I sent them my ECU for testing, which they said they did & found the vehicle would not accelerate, so after a long long long wait they finally supplied a replacement ECU reflashed it with my MAP & it all tested fine. So after a 6 week wait I finally got my replacement ECU yesterday & put it in this morning and low & behold I have exactly the same ****** problem. To say I am slightly ****ed would be an under statement, I somehow feel I have been had & they did not test my old ECU at all & have just charged my 450 quid for a replacement. The only positive is I now know I can rule out the ECU as the problem.

From the moment I plugged it in & tested it, I had exactly the same faults as before even before stating the engine. I had a quick look and the throttle supply V at the pot is 0 on Hawkeye but I think this is the doing of the ECU because if you start it up with a throttle input & keep the engine is running at a high RPM the the management light is off but as soon as it gets back to near idle the ECU seems to pull the supply voltage, you then get the management light on & the throttle is no longer responsive. When it is running there is some times a light miss, the injector balances are all between about +/- 5 rpm.

Now with a new throttle pot, mass air flow sensor & ECU as well as a rewired harness from the ECU to the throttle pot I am really stuck on what to do next.

Is there much chance it is a crank position sensor as this is a critical sensor it has never faulted on Hawkeye so I have my doubts it is the culprit but there is obviously some critical component somewhere along the line causing my grief.

Finally I think I can see light at the end of the tunnel.

With not knowing what to do next I decided to try a crank angle sensor, all I could find locally was a Britpart one which I threw in this arvo and low & behold it seems to have fixed the problem. Time was short and I have to put the car back together again before I can test drive it hopefully either tomorrow or Friday to confirm the fix.

As soon as I fitted the new sensor it fired up perfectly as it always did but the engine light didn't come on and I again had throttle control, I shut it down cleared all of the codes fired it up again & it all checks out fine with no driver demand faults.

Al I can think of is the signal from the crank angle sensor was weak or similar, it was enough for the engine to start, but not logging a fault, the signal must not have been good enough for the ECU to manage so the ECU pulled the power to the throttle pot to put it in limp mode & logged it as a driver demand fault. I wish the ECU had logged the crank angle sensor fault earlier as it would have saved me a hell of a lot of time, money & grief. It also explains the slight miss I was sometimes having,

Now to order a genuine sensor & I will keep the Britpart one as a spare.

Once I have it all back together again & on the road I will hopefully be able to give one final update and close the case. :angel:

I was just searching about TPS faults for the Td5 and came across this thread.Since you have changed the crank angle sensor has it still been running good?

Sadly not, since I replaced the CAS it did fix the problem, everything had been running well for about 500km but this morning I was out in the desert on a heavily corrugated sand track and the engine management light came on several times & the engine again went back to idle. I was able to turn the engine off each time and reset the fault and was able to drive home with no further issues, I am yet to check which fault codes were flagged up via Hawkeye.

So I am back to square one, but it is now an intermittent fault which I think must be a wiring problem, as all of the critical components have been replaced, TPS, CAS, ECU & mass airflow sensor.

It is a bummer as I have a 3 day desert trip planned in it next month but unless I can find a confirmed fault I doubt I can use the vehicle on the trip as it is into some pretty big dunes and the last thing you need is to be stuck at idle.

The other thing is now that the fault is mostly fixed it is going to be much harder to find the problem as the engine is now running perfectly most of the time. I think in inspecting the looms & cleaning all of the plugs I have disturbed the problem but it seems is still there on rough roads.

Sadly my problem still has not been cured, it is back similar to before but I am now getting a new code which has had little mention on the internet.

3120 high speed crank synch loss logged

Has anyone seen this one before, to me it would seem related to the crank angle sensor.

I was in the desert last weekend and need a tow out sadly, at least I was towed by a G Wagon and not a toyota. I think I now need to remove all of the conduit covering all of the wiring harness I can get access to, to see what I can find.

Anyone else got any thoughts on where to head next apart from burning it.

Disregard just read a post missed.

Sadly I missed what you initially said, I was getting excited that someone had come up with something new. :o

Hello,
I had a similar problem about engine check light and no throttle response it turned out to be a short in the fuel temp gauge or the feed wires to it going to earth, changed wires and temp sensor never again........ seems as though you have tried everything else.
Ian

Thanks mate, I think it will be something like that, an unrelated sensor or wire which is throwing the spanner in the works.

I will check it out.

Well after many months I think I have finally found & fixed the problem. I had pretty well lost interest in working on it so it has spent quite a bit of time sitting in front of our house as a static display & I would tinker on it here & there for a while when I found a bit of interest..

A few weeks back I spent 3 hrs shaking & wobbling all of the looms & harnesses I could get my hands on with the engine idling. During this 3 hr period I was able to bring on the engine management light 3 times but each time was when I was shaking a different loom.

3120 high speed crank synch loss logged

This fault which had previously logged made me think it was a dirty signal from the CAS, I found a small crank in the insulation to one of the wires in the back of the CAS plug which I felt may have been letting in oil of have damaged the wires. I ordered a new plug & wires kit from Ebay in the UK & soldered it in place and it seems to have fixed the problem. I have been driving it for a few days & gave it a good work out over a rough corrugated road and so far so good.

The more I looked at the CAS loom the more sense it made as it is quite a short loom which connects to a large loom which also has the positive lead running to the starter in it, so I think this large loom was moving when going around LH corners and over bumps which would give me the problem. With the new plug & loom I installed I left the loom much longer than original so there is no tension on it from the large loom below.

I am starting to think I have finally nailed the problem after many months, hours & money spent.

I will keep you updated once I get some more miles on it & fingers crossed I can close this thread.

Thank you all who offered help & advice. It was greatly appreciated. :thumbsup: