Hole burnt through a piston

[lynno3103]

Hi, I own a Hilux dual cab D4D 2007 with 85,000km on the clock. It suddenly lost power and started to run as rough as a chaff cutter and blowing black smoke out of the exhaust. Diesel mechanic diagnosed problems with number 4 cylinder. After removing the head they have found a hole burnt in the piston. Has anyone else experienced this problem? I have had this car since new and serviced regularly by Toyota. I would appreciate any assistance, help or comments.

[amitch888]

Gawry is going though this at the moment, fairly sure it was the same issue!
viewtopic.php?f=3&t=11825&p=176449#p176449

Do you have a chip or any engine mods? Had injector issues or previous work?

Cheers, Mitch

[lynno3103]

I have a Steinbauer Power Module which was installed 4 years ago. No previous problems at all with anything.

[Ggn25]

I'm not saying too much , for fear of being flamed , 3 engines at work all have had holes, cracks in pistons and all of them have had chips on them .

1 & 1 = 2

Had you run the vehicle for an extended period of time with it running rough , misfiring or severe knocking . An injector issue ?..

[lynno3103]

No. As soon as it occurred it was quite severe so I stopped immediately and called RACQ for a tow. Understand what you say about power chips and appreciate your input.

[cambelt]

Hello
Dud injectors can cause this as can a overfueling chip . 4 years of running a chip is a good test , Do you tow or work it hard ? Even a stock 1KD will see exhaust temps of 580 c .
If you shut it down straight away then you prob avoided any other damage , they re piston and ring well, good bores ( put a set of 4 in tho ) . Allways seem to no 3 or 4 that die . And after your done get a EGT guage.
Dave

[D4DEVIL]

what sort of coin are you looking at for 4 pistons replaced?

[aandy]

This is what concerns me about chips, anything that can change the duration/pressure of injection will change the penetration of fuel in the combustion chamber possibly burning pistons/bores/valves etc..

I once changed twelve 320mm diameter cylinder liners that were ruined by incorrect injector nozzles.

[GreenHilux Guy]

I suspect the chip was not the fault. My mechanic Greg is rebuilding his block after ingesting a tank of rubbish diesel from a big brand servo. The high pressure common rail system with a few drops of dirty water can cause lethal damage. The water went through his filter, entered the chamber and the pressure used the water like a plasma cutter cracking the cylinder head.

[Tacolux]

So where do we stand with the servos for dishing out this crap? There are servos near us now advertising 100ron pulp again. Used to be able to get 105ron.

Which diesel are you using. We did this massive trial at work with BP Vortex in our Haul Truck fleet. Not sure what came of it. They were looking for extra economy.

[danmcccc]

I suspect the chip was not the fault. My mechanic Greg is rebuilding his block after ingesting a tank of rubbish diesel from a big brand servo. The high pressure common rail system with a few drops of dirty water can cause lethal damage. The water went through his filter, entered the chamber and the pressure used the water like a plasma cutter cracking the cylinder head.

this is sooooo tru mate....crd fuel pressures reach 20,000psi + thats enough to make water cut anything

[JUSTAUTOS]

Ford ranger are 40,000psi we work on common rails every day seen some pretty cool stuff

[Ggn25]

Most max pressures on denso stuff is around 165000 Kpa ( 23900 psi) . Piezo injectors are around 29000psi .

Idle pressures on hilux is between 35000 to 38000 Kpa max pressure for leak test is 160000 to 175000Kpa, never heard of 40000 psi system yet .

I see chips that raise the idle pressure to over 50000kpa

[toyboata]

I've just had a 2008 Kia Sorrento CRD towed into work that is missing big time and blowing smoke.
Lifted hood and oil everywhere.
Removed engine cover and no. 4 injector is sitting 3 inches higher than the rest.
The bolt securing it's clamp to the cylinder head has had the head sheer clean off and there's diesel and oil everywhere.
Looks like its poured fuel in to the cylinder causing hydraulic lock up and the weakest point is the bolt holding the injector and the pressure has blown it out of the head.
Sent the injectors to be tested and I'm pretty sure they'll come up as f$cked!
Next is to pull the head off and see what other damage there is.

[Ggn25]

Most max pressures on denso stuff is around 165000 Kpa ( 23900 psi) . Piezo injectors are around 29000psi .

Idle pressures on hilux is between 35000 to 38000 Kpa max pressure for leak test is 160000 to 175000Kpa, never heard of 40000 psi system yet .

I see chips that raise the idle pressure to over 50000kpa

[Gawry]

All the best with it Lynno
It's been a painful experience.

[tcurve]

So do you guys think it was a chip that caused it or not? I am looking for a chip at the moment but dont want to put it on a d4d with 260,000 on the clock if this will happen

[danmcccc]

So do you guys think it was a chip that caused it or not? I am looking for a chip at the moment but dont want to put it on a d4d with 260,000 on the clock if this will happen

mate look at it this way, how many new diesels are running chips and how many have had this problem? like 0.01%? i wouldnt be worried, if it was a major problem the people that sell the chips would be out of business

[toyboata]

I don't think chips are the cause of these problems.
It's usually dodgy fuel or just plain failure of the injector. Chip could add to premature failure in some cases but I think injectors get tested well beyond the fuel pressures that can be ascertained by installing a chip.
If the injector fails, then having increased fuel pressure due to chip can exacerbate the problem and possibly cause extra damage, however with standard fuel pressures in excess of 30,000psi, chip or no chip the fuel is gonna cut through pistons like butter if there's massive injector failure.
Personally, I'm happy to risk it for the benefits I get from my chip.