EDIT: updated diagnostics here. From what I've collated from the forum, the biggest stand-out is my Target EGR Position versus EGR Lift Sensor Voltage % - rather than being within 15 of eachother, they're 40 apart.
Hi all - I'm having similar symptoms to this now.
'06 with 141,000km. Getting a puff of black smoke under acceleration (near or above 2,000RPM). It's only a puff but it happens consistently enough for me to enquire. Hitting it in second gear gets a bit of a plume but that's expected when you're hitting it...
Did all the usual maintenance suspects last night. The MAF sensor was a little dirty on one side and the MAP filter was clear but the smoke persisted. I also have a catch can fitted which I emptied - the oil was black and it wasn't full.
Injectors, fuel lines, suction control valve - all replaced 21,000km ago. EGR and Intake Manifold was also cleaned at the same time (catch can went in BEFORE the clean).
Serviced 2,000km ago, so the oil's fresh and all filters were replaced (air, fuel, oil - all genuine Toyota, and a new filter for the secondary fuel filter).
The only recent work done was the replacement of my rocker cover (old one was was cracked) which included new gaskets and associated fittings, and a clean/degrease of the area affected by the crack. I also thought it might've had to do with my battery being disconnected and thus the ECU reset? Unsure. I also had the clutch and brakes overhauled but that's completely unrelated I'd think...
Fuel economy is also down. I usually fill up at 640km (prior to the warning light) but my second last tank was 580km at the warning light. Last tank was 620km before the warning light.
This is my last diagnostic (September 2016). I have access to Techstream so I'll run another on Saturday.
My next steps are to check hose fittings, hose clamps, sensors, wiring, and reset the ECU (via battery disconnect and headlights
as boxhead55 recommended).
Is there anything else that should be on my agenda before considering bringing it to a mechanic?
Cheers.