IS220D 2007 Injector problem - Feed back Volume #4 +5.0 mm3/st - White smoke

[jomjom3535]

Hi 

Problem with Injector number #4   - 5.0 mm3/st   

1) Swap injector #4 with #3   no change in #4 still 5.0 mme/st   - so cylinder 4 always giving 5.00 mm3/st no matter what injector 

2) Put new reconditioned  injector in #4  - no change in the feed back volume   

3) In active mode stalled fuel  injector 1,2,3 & 4  no change in injector #4 

What is the problem 

  Is in the DCU, wiring issue , seal or cylinder valve issue  

Have the full readings , i can post  

 

[johnatg]

I'd suggest that you have a head gasket failure. 

Any signs in the coolant or coolant level? 

Any signs in the oil? 

Can you get a compression test? 

[jomjom3535]

The value is + 5.00 mm3/st  

Was thinking head gasket , at full rev there is some movement in the coolant but though that was normal, i will try a compression test see what i get across the cylinders 

[jomjom3535]

But   - after a while few min  the smoke turns black , and the exhaust leave black soot on ground , temp stable, car judders on acceleration and sometimes gets 

Injection malfunction code P1238  but can clear and does not come back for a long period 

[jomjom3535]

OK did compression test through the glow plugs , Cylinder #1  320 psi  , Cylinder #4 325 psi (suspect injector at 5.0 mm3/st) 

So what now 

[johnatg]

P1238 doesn't necessarily mean an injector problem. It can be set when a cylinder is operating poorly. 

I still think head gasket - common on IS220d. 

It may be OK with a compression test but show a problem when running. A sniffer test on the coolant might show combustion gases. 

I'm clutching at straws though. 

[jomjom3535]

I will connect pipe and bottle of water to overflow , remove the rubber on the cap and see if i get any bubbles - should i let it warm up 

[johnatg]

PS beware of excess fuel in the exhaust - it can overspeed and blow the turbo. 

[steve2006]

It’s not the 5th injector throwing fuel in when it shouldn’t be is it?

What’s the EGR valve looking like?

[jomjom3535]

Only 120K klm on engine 

 

[johnatg]

I think you'll get bubbles anyway - may not be very conclusive 

[jomjom3535]

Just replaced 5th Injector with a new one no change on smoke  and cleaned EGR few times still smoke , still injector 4 at +5.0 mm3/st 

[jomjom3535]

Yes i think i will get bubbles anyhow - so will check  

 

[steve2006]

Have you got diagnostics for live data, injector opening pulses?

[jomjom3535]

 

Data readings Idle for IS220D 

 

2008    IS220 

2/21/2021 8:19:34 PM

[Engine Stored] System

[Parameter]    [Value]    [Unit]
Vehicle Speed    0    km/h
Engine Speed    792    rpm
Calculate Load     25.4    %
MAF    7.53    gm/sec
Atmosphere Pressure    99    kPa(abs)
MAP    95    kPa
Coolant Temp    55    C
Intake Air    13    C
Intake Air Temp (Turbo)    21    C
Engine Run Time    41    s
Initial Engine Coolant Temp    53.7    C
Initial Intake Air Temp    17.5    C
Battery Voltage     14.1    V
Alternate Duty Ratio    35    %
Accel Position     0.00    %
Accel Sens. No.1 Volt %     15.6    %
Accel Sens. No.2 Volt %     32.1    %
Actual Throttle Position    86    %
Throttle Close Learning Val.     17.3    deg
Diesel Throttle Learn Status    OK    
Throttle Sensor Volt %     21.5    %
Throttle Motor DUTY     42.3    %
Injection Volume     9.60    mm3/st
Inj. FB Vol. for Idle     3.68    mm3/st
Inj Vol Feedback Learning     0.9    mm3/st
Idle Signal Output Value    1    
Injection Feedback Val #1    -3.5    mm3/st
Injection Feedback Val #2    -1.5    mm3/st
Injection Feedback Val #3    -0.7    mm3/st
Injection Feedback Val #4     5.0    mm3/st
Pilot 1 Injection Period    0    us
Pilot 2 Injection Period    251    us
Main Injection Period    426    us
After Injection Period    0    us
Pilot 1 Injection Timing    -19.2    deg
(CA)
Pilot 2 Injection Timing    -8.3    deg
(CA)
Main Injection Timing    -3.9    deg
(CA)
After Injection Timing     22.3    deg
(CA)
Injector Memory Error    No Error    
Target Common Rail Pressure    38960    kPa(abs)
Fuel Press    38530    kPag
Fuel Temperature    34    C
Fuel Route Switching Valve    OFF    
Intank Fuel Pump    ON    
Target Pump SCV Current     1246.3    mA
AF Lambda B1S1     0.997    
AFS Voltage B1S1     0.00    V
AF Sensor Learning Value     1.85    V
Target EGR Position     19.2    %
EGR Lift Sensor Volt %     62.8    %
EGR Close Learn Val.     3.72    V
EGR Close Lrn. Val.     3.72    V
EGR Close Lrn. Status    OK    
Target Booster Pressure    93.69    kPa(abs)
VN Turbo Command    73    %
Exhaust Temperature B1S1    76.2    C
Exhaust Temperature B1S2    73.1    C
DPF Differential Pressure    0.300    kPa
Diff. Press. Sensor Corr.    0.2    kPa
Exhaust Fuel Addition FB     1.00    
DPF Thermal Deteriorate    Normal    
DPF No Activate    Activate    
DPF PM Block    No Block    
Catalyst Memory Error    No Error    
DPNR Status Reju (S)    Standby    
DPNR/DPF Status Reju(PM)    Standby    
Starter Signal    OFF    
Starter Control    OFF    
Starter Relay    OFF    
ACC Relay    OFF    
Neutral Position SW Signal    OFF    
Stop Light Switch    OFF    
A/C Signal    OFF    
# Codes(Include History)    1    
MIL ON Run Distance    0    km
Running Time from MIL ON    0    min
Time after DTC Cleared    14    min
Distance from DTC Cleared    0    km
Warmup Cycle Cleared DTC    0    
TC and TE1    OFF    
Electric Fan Motor    OFF    
 

 

Data Reading after 40min 

2008    IS220 

2/14/2021 7:32:11 PM

[Engine Stored] System

[Parameter]    [Value]    [Unit]
Vehicle Speed    0    km/h
Engine Speed    949    rpm
Calculate Load     16.0    %
MAF    17.82    gm/sec
Atmosphere Pressure    100    kPa(abs)
MAP    106    kPa
Coolant Temp    80    C
Intake Air    9    C
Intake Air Temp (Turbo)    30    C
Engine Run Time    2444    s
Initial Engine Coolant Temp    80.6    C
Initial Intake Air Temp    26.8    C
Battery Voltage     14.1    V
Alternate Duty Ratio    33    %
Accel Position     3.90    %
Accel Sens. No.1 Volt %     20.3    %
Accel Sens. No.2 Volt %     36.4    %
Actual Throttle Position    -1    %
Throttle Close Learning Val.     17.2    deg
Diesel Throttle Learn Status    OK    
Throttle Sensor Volt %     69.8    %
Throttle Motor DUTY     58.8    %
Injection Volume     5.95    mm3/st
Inj. FB Vol. for Idle     0.38    mm3/st
Inj Vol Feedback Learning     0.9    mm3/st
Idle Signal Output Value    0    
Injection Feedback Val #1    -2.1    mm3/st
Injection Feedback Val #2    -1.5    mm3/st
Injection Feedback Val #3    -1.1    mm3/st
Injection Feedback Val #4     4.6    mm3/st
Pilot 1 Injection Period    146    us
Pilot 2 Injection Period    161    us
Main Injection Period    125    us
After Injection Period    0    us
Pilot 1 Injection Timing    -14.0    deg
(CA)
Pilot 2 Injection Timing    -9.9    deg
(CA)
Main Injection Timing    -5.8    deg
(CA)
After Injection Timing     21.4    deg
(CA)
Injector Memory Error    No Error    
Target Common Rail Pressure    38470    kPa(abs)
Fuel Press    37310    kPag
Fuel Temperature    46    C
Fuel Route Switching Valve    OFF    
Intank Fuel Pump    OFF    
Target Pump SCV Current     1261.0    mA
AF Lambda B1S1     0.998    
AFS Voltage B1S1     0.00    V
AF Sensor Learning Value     1.85    V
Target EGR Position     0.0    %
EGR Lift Sensor Volt %     75.0    %
EGR Close Learn Val.     3.75    V
EGR Close Lrn. Val.     3.75    V
EGR Close Lrn. Status    OK    
Target Booster Pressure    95.07    kPa(abs)
VN Turbo Command    73    %
Exhaust Temperature B1S1    120.6    C
Exhaust Temperature B1S2    116.8    C
DPF Differential Pressure    -0.579    kPa
Diff. Press. Sensor Corr.    0.3    kPa
Exhaust Fuel Addition FB     1.00    
DPF Thermal Deteriorate    Normal    
DPF No Activate    Activate    
DPF PM Block    No Block    
Catalyst Memory Error    No Error    
DPNR Status Reju (S)    Ready    
DPNR/DPF Status Reju(PM)    Ready    
Starter Signal    OFF    
Starter Control    OFF    
Starter Relay    OFF    
ACC Relay    OFF    
Neutral Position SW Signal    OFF    
Stop Light Switch    OFF    
A/C Signal    OFF    
# Codes(Include History)    0    
MIL ON Run Distance    0    km
Running Time from MIL ON    0    min
Time after DTC Cleared    35    min
Distance from DTC Cleared    0    km
Warmup Cycle Cleared DTC    0    
TC and TE1    OFF    
Electric Fan Motor    OFF    
 

 

 

[jomjom3535]

Any suggestions

 

[jomjom3535]

Any suggestion how to fix

[jomjom3535]

Tested wiring to 4th injector all ok I removed 4th injector and connected it outside engine to observe pulse and diesel spray looks ok when running ran car hot and forced regen which worked at hot smoke disappears but 4th injector still reads +5 mm3/st next day car back smoking  at idle get white smoke then black with soot on ground 

[jomjom3535]

Going to try purge next

[jomjom3535]

Injection volume jumping at idle when warm engine shudders then cycles to normal back shudder every min 

[CazzyG]

On 3/9/2021 at 9:24 AM, jomjom3535 said:

Injection volume jumping at idle when warm engine shudders then cycles to normal back shudder every min 

Hey Jomjom did you ever get to the bottom of this issue with car smoking?

My DPF was removed and 5th injector turned off, car has been driving perfect but started smoking right after refuelling. Now seems like there is fuel issue (loss of ignition or misfire ) when it gets to temperature.

Exhaust smells like melting metal maybe very high temperature. Cheers