[Jack Sparrow]

Originally Posted by AutoIndian

......
That you for sharing your experience Jack Sparrow. Was there any issue with the FIPs of particular batches of Innova? In that case Toyota should have recalled cars from there batches and done a voluntary replacement.

Nothing that I could recall wrt to FIP's. Tried researching during the failure but could not find any and Lanson Toyota did not say anything on mailers from Toyota for voluntary replacement. Either way my car was 4+ years old at the time of replacement and Toyota only gives a Std 3 yrs/100 K kms warranty. Was helpless and had to repair it to keep the car running.

Originally Posted by speedmunster

Jack Sparrow, your thread was one of the very helpful ones that I had read while going through the whole mess. The difference between your car and mine was the error codes. Mine showed none.

Glad they were useful. Thats the beauty of this Forum.

Originally Posted by AutoIndian

Another point I have to take care is to tank up the car only from good reputed bunks (especially COCOs). I have the habit of going to remote places/ unchartered territories. Will have to make sure not to tank up from remote areas else be prepared for FIP issues.

Edit:
I tried to search for this thread, but unfortunately I could not trace any thread started by Jack Sparrow. Would you or Jack Sparrow mind sharing the url?

We normally tank up in a reputed bunk within the city and stick to a single bunk always. All my fillings for Innova and Scorpio have been through a good Petrol bunk and I maintain my logs....Could be a case of adulterated fuel from one of the highway trips before the failure. Just got unlucky on this and it was the only major breakdown with my car.
I did not create a thread but posted it in CDM's thread regd fuel pump issues with Innova. Link below.
http://www.team-bhp.com/forum/techni...em-issue.html#

Originally Posted by GTO

One of the most common causes of fuel pump failure is running the tank on fumes (low fuel). ......I never let my cars go below the 1/4th level.

Agreed GTO. I tank up my cars once it reaches the 1/4 mark and never run low on fuel. I have psychological problem too when I see it below that level. Always have a feeling that I would stall somewhere.

Originally Posted by AutoIndian

......Speedmunster and Jack Sparrow, do any one of you recollect running your car with almost dry fuel tank or at a fuel level well below the reserve? Or to put it in perspective have you ever done a tankful where the quantity of diesel that went in was very close to 55 litres?

Nope. Normally it takes in 43-44 ltrs of fuel for every tank fill. So is the case with my Scorpio which takes in 45 ltrs(over the last 74 refills).

[speedmunster]

A funny thing I forgot to mention in the original post is something that I found out about the Innova's ECU. During all the researching that was being done before the repairs, I had called Abhishek @ Kiirus to ask him if there could be something wrong with the ECU and if he could take a look at it when he came down to Hyderabad the next time. He said that this definitely does not seem to be a case of a malfunctioning ECU and it was something else that was causing all the trouble.

Next question to him was whether he could remap the ECU of the Innova. And the answer: The Innova's ECU cannot be remapped. This particular ECU happens to be based on a very old design and one of the very few ECUs in the world that can not be remapped. The only other thing that can be done to increase power and torque is to add a Diesel tuning box.

This information, I thought would be useful to some of us 'poor' Innova owners.

Cheers.

[samish_g]

Originally Posted by speedmunster

Mr. Afzal Khan himself hooked up the OBD scanner to my Innova and tried to check for any fault codes. Again, no error codes showed up. He was nice enough to call up the engineers at the Denso India headquarters and discussed my car’s problems in detail. They too suggested to change the fuel pump. Now coming to the price: Star Diesel quoted Rs. 30800 for the fuel pump and Rs. 2000 for labour charges. The price difference was astonishing to say the least. Got the fuel pump changed at Star Diesel and what a difference that has made. The car runs better than a new Innova, starts like it should, has immense torque through the gears and the acceleration is unbelievable. It now feels better than it felt when we bought the Innova.

Congratulations @speedmunster for getting the Innova back to its pristine condition.
Please pardon me if I am being rude, but, Star Electronic Diesel Engineers, the place where you got the fuel filter changed (authorised dealer for Denso) does not appear in the listed service centers in their website. The website can be referred to here.

Regards,

Samish

[speedmunster]

Originally Posted by samish_g

Congratulations @speedmunster for getting the Innova back to its pristine condition.
Please pardon me if I am being rude, but, Star Electronic Diesel Engineers, the place where you got the fuel filter changed (authorised dealer for Denso) does not appear in the listed service centers in their website. The website can be referred to here.

Regards,

Samish

This is the page I saw.
http://www.denso.co.in/Denso%20Service%20Network%20Fuel%20injection%20pum ps%20south%20zone.aspx

[manishk123]

Originally Posted by GTO

One of the most common causes of fuel pump failure is running the tank on fumes (low fuel). In many fuel pumps, the lubrication is provided by the fuel itself. I hate to see cars running with the 'reserve fuel' light showing. I never let my cars go below the 1/4th level.

Thanks for that valuable info. My driver recently ran my honda city out of fuel. After tanking up the car wouldn't start. My mechanic gave a few taps to the fuel pump and it fired up. However he warned me that it will stall anytime unless the fuel pump is replaced. I though he was just trying to make a quick buck. However, the car had become unreliable ever since, stalling every few days, and then starting up after a struggle. Finally after reading this thread i realised I will have to change the fuel pump. Cost quoted for imported pump Rs.4000 + 800 labour. Company cost is around Rs.17,000. Going with the mechanics suggestion since car is now around 8 years old. Will probably sell it in a year or two.

[asit.kulkarni93]

Surprised to see an issue occur in an Innova.I hope your car isn't facing any issues now.

Originally Posted by speedmunster

The Innova's ECU cannot be remapped. This particular ECU happens to be based on a very old design and one of the very few ECUs in the world that can not be remapped.

While this was true in 2015, it has changed in 2016. Toyota ECUs (Innova, Fortuner, Etios, Liva) can be remapped now. Coincidentally, the first Innova that got remapped in India belongs to a BHPian in Pune.

Asit

[CJP]

I have a somewhat similar problem, Toyota Innova 2009 model, covered 2,25,000 plus km. Got the injectors serviced recently and the car has been a dream to drive.

Now, the car has developed a late start problem, takes a few cranks to start in the morning. I took it to Toyota Service at Kanakapura Road. And after running their diagnostics, they confirmed that the pump is developing slightly lower pressure, especially after stopping overnight.

Nandi Toyota's charges for replacing the pump is Rs.65K on exchange and they charge Rs.115K for a new pump without exchange. Denso authorized dealer only charges Rs.31K for a new pumpe on exchange. Even if we add about Rs.10K for labour and consumables, these official service centers are making a killing on these jobs.

Which reminds me, when I contacted Viva Toyota at Nayandahalli for servicing my injectors they wanted to charge Rs.10K per injector, labour and consumables extra - estimated to be about Rs.75K for the full job. Whereas the authorized Bosch/Denso service center only charges only Rs.800/- per injector add labour cost of about Rs.2K for dismantling and fixing and consumables (seals etc.) about Rs.2K.

After reading this thread, I called up Denso Service, Tarun Diesels at Kalasipalayam. And they confirmed the following
- a new diesel pump in exchange costs about Rs.31K
- pumps with serial numbers starting with 044 - cannot be serviced, will need to be replaced. Pumps with other serials can be serviced for under Rs.10K

Since they only service pumps, I will have to hand carry the pump for the service, which means I need a reliable garage to remove the pump from the car and then refit it correctly using appropriate seals gaskets etc..

Need help with identifying a reliable garage in South Bangalore, any help with this is much appreciated. My last experience with Bosch Car Service at Nagarabhavi was not great.

[dineshnan]

It all started about 2 years back. My Innova (2008 2.5V ODO now 159000 Km) started showing steady yellow engine check light and giving up acceleration. If I press accelerator pedal, nothing to happen only raising sound. So I would have to switch off the engine and restart (If I don't stop, then car itself would stop). The car then would run normal after start or after few start stops. I took the car then to a local mechanic where he scanned and came up with code P0093.
1. The code primarily indicates major fuel leaks. Checked everywhere but no leaks found. Diesel filter cleaned and pumped up to remove any air.
2. The problem again popped up. This time diesel filter replaced. Car run smoothly for few months. No issues at all but again same issue.
3. Car taken to TASS Cotton-green. They replied no code coming in scanner. I showed the snapshot taken previously. They told to replace fuel pump. Estimated cost 85-90000/-. I requested to repair but they said they don't repair anything only replace. Took car back as it is.
3. Problem appeared again. This time diesel tank pulled down (local mechanic above). Cleaned everything. Small filter inside also cleaned.
4. Car then taken to TASS chembur as well as Turbhe, no resolution. They ran the car with scanner connected but said no code appearing what to do. If we replace any part and problem appears again then it would be a set back. I agreed but what about the issue, how to resolve.
5. Car run smoothly for few months and again same issue. Car again taken to same local mechanic who scanned it again to see same code P0093.
He suggested to change fuel pressure switch. He then called spare parts supplier and narrated the issue. The supplier said it may not be switch issue but the pump itself and quoted 1.25L for the pump. I was so frustrated with the problem that I finally agreed to replace the pump but not with local mechanic, with TASS. For a try, mechanic suggested to go with second hand pump. He was advising against servicing the existing pump. Mechanic was saying, very rarely it comes out good after servicing, these guys normally would increase servicing cost (cheating expected). Second hand pump from CST market is an option. It is normally a pump removed from old scrapped cars. I asked what about its performance guaranty. After some phone calls one supplier agreed to give pump at 22K and 3 days warranty. Mechanic advised to go for it. I also agreed. Initially we thought it was Bosch pump in use but after removal we found it was Denso pump.
First spare pump which was received failed, car refused to start. I was totally scared. (My dilemma was why car would run without any issues for several kms, means it is not pump issue but something else) Then he sent another one after two days. It worked. This time we agreed for
7 days warranty period. Also based on the pump switch, mechanic says it may be 5-6 years old pump (who knows).
Drove the car on Mumbai-Goa high way up to Nagothane and came back without any issues (so far). Looks like it was fuel pump issue. Hope it
is resolved now. Old pump with me now, will try to service it somehow.
P.S - with all these frustrations, almost decided to buy new crysta (but now will wait )

[speedmunster]

Originally Posted by dineshnan

Old pump with me now, will try to service it somehow)

Hi Dineshnan. I would highly recommend you speak to Afzal Khan and send over the fuel pump to Hyderabad to get serviced. Pm me if you want his number. On the other hand, your existing pump seems to be working fine, so why do you want to spend money on the old pump.

Cheers

[dineshnan]

Hi Speedmunster
Existing pump is not yet extensively tested due to lockdown and all. Also if affordable, it would be great to fix the broken thing, just in case…

[norhog]

Originally Posted by speedmunster

As a last resort, we took the car to the local Denso Service centre (That is the make of the Innova Fuel Pumps) and what a revelation it was. The service centre – Star Electronic Diesel Engineers is located at LB Nagar and is run by a young gentleman named Mr. Afzal Khan. They are also the distributors for Holset Turbochargers and they carry out repair work on automotive and marine fuel pumps and turbochargers. I strongly recommend Star Diesel for all engine related, turbocharger related and fuel pump related work of all brands of cars be tested here and an opinion sought before blindly heeding advice of the authorised service centres. Mr. Afzal Khan’s phone number is 90000 16661. (PS: I am in no way connected to the owners or the company in any way other than being a very satisfied customer)

Good to hear your success in replacing the pump for half the cost.
Just to confirm as it is not mentioned any where explicitly.
This pump fitted by STAR Electronics, is it a brand new unit or a refurbished/overhauled one.

Thanks in advance.

[speedmunster]

Originally Posted by norhog

Good to hear your success in replacing the pump for half the cost.
Just to confirm as it is not mentioned any where explicitly.
This pump fitted by STAR Electronics, is it a brand new unit or a refurbished/overhauled one.

Thanks in advance.

That was a brand new unit and not a refurbished one.