Shahpor

Nice.  No matter how hard I tried, my local dealer never seemed to have a new IS for me to try. Perhaps I look too poor? 

Anyway, I assume it is in to have the new pump fitted?  Are they charging you for the labour?

Is the fault temperature related perhaps?  I am under the impression that the symptoms decrease when the weather is warmer outside?

Gary, did you ever ask the dealer about the fuel temp sensor?  It would explain why it seems to be temperature related.

As for the problems you guys are having, I don't think it is a specific diesel problem but rather a modern car problem.  Newer cars have just become so complex that it is getting harder to diagnose issues.  According to the manual, our cars have 19 ECU's!  I remember when 1 was enough.

The other factor is that complexity adds more potential failure possibilities, and since diagnosing difficult problems hasn't changed from the past, guessing which part has gone wrong has become more difficult.  This leads to issues like you guys are having when you either have to choose which part to replace, or just keep changing until the fault is cured.  Not the most cost effective repair 

Have you guys seen the new BMW 7 series?  Can you imagine trying to diagnose a fault on that in 10 years time?  What we need is a much more sophisticated fault finding system built into the cars systems.  But, of course, that adds cost and it gains the manufacturers nothing when selling new cars, so why would they bother?

£4456 is a joke.  What exactly would they do for that amount?

Perhaps some secondhand injectors from eBay?  The TechStream software should be able to code them?

Yeah, it appears there are gearbox brackets on the front and rear of the transmission.  You might also need to undo the prop shaft donut.  Doesn't look particularly tricky, but I know how much of a pain working under a car is without a ramp.

By the way, you have the Lexus repair manual, don't you?

That is actually rather clever.  Never used a pry bar and a spanner at the same time before.

As for the clearance, can't you loosen the engine mounts and try and tilt it forward a little?

These bolts:

Well, blue smoke indicates that his car is burning oil, so yes, it sounds like his engine isn't in the best of health.

My dad had a Mercedes 560SEL which used to smoke on acceleration so much that the cars in the rear view mirror would disappear   What was impressive was how long the engine continued to run that way, but then again, it was possibly the laziest V8 ever made 

You actually need to hold SET and 1 together until it beeps, but apart from that, you are right 

Hehe, yes I am very curious how that conversation is going to go 

£110 for a pump is very good.  Was it from a low mileage car?  Either way, as long as it's work, that is the main thing.

After what you have been through (and, if there is any justice in this world, get it working properly), you might want to consider getting an extended warranty for it.  After reading this thread, so glad I got mine. 

If you are ever near Hampshire way, you can have a look at my 220d.

As far as fuel consumption, mine varies greatly depending on whether I use it in London traffic or on a motorway journey.  Around town I am managing about 25-28mpg.  On the motorway run, 45-50mpg if you drive carefully.  At the moment I am doing a mix of both types of trip, so am averaging 38-40mpg.

How many miles a year do you think you will cover?  If it is not a lot then the 250 really is the way to go. 

Excellent news, well done! 

You should go back to the dealer and tell them.

Second hand pump time?

Well, this made my day 

Nah, but seriously, we may have had our disagreements, but you are obviously a helpful and active member of this forum.

The CL looks very nice, and no doubt goes very well.  Good luck with it.

Second hand pump maybe?  Quite a few 220d's being broken on eBay?

Also, if you do manage to loosen the bolts, can't they take it back for diagnosis?  After all, if they had gotten the pump off, weren't they going to test it?

Good idea.

No reason why you can't do both at the same time.

I really hope you manage to get it off.  If I can help in any way, let me know.

Not quite sure how you get at it, but would it help if you took the bonnet off?

Don't give up yet mate.

Like I said, you have nothing to lose from contacting either the dealer or Lexus UK.  See if you can get your local dealer to agree to tell them that the bolts were done too tight and not to spec when the engine was done.  Having a full Lexus history also backs up your claim that no one else has been messing with it.  Even if you didn't buy the car from the Cardiff dealer, I assume you have proof that they were the ones that did the work?

I agree that the odds are not in your favour, but stranger things have happened.

Also, since the car still runs, I would at least take it to a local garage and get them to have a look.  Again, no harm in trying.

 unbelievable mate

This can't be the end of it.

Off the top of my head, can't you take it back to Lexus Cardiff if they screwed up the installation?

Or perhaps take it to an independent who might be able to undo the bolts for you?

Apply to Lexus UK for some goodwill considering it was one of their dealers who probably screwed up the original job?

There must be a way to get it off other than taking the engine out! 

The car has a fuel temp sensor?!?!

Anyone else suddenly miss carburetors? 

You won't be able to see the top of the valves from the top of the head because the valve train and oil seals will be in the way.

With the inlet manifold off, the back of the valves should be visible in the ports.

Man, that sucks Gary. 

At least it appears your Lexus dealer is determined to find the fault, hopefully with very little or no extra expense.

Although, if things on the car really have improved like you say, then it seems there was more than one worn or faulty part, so at least progress is being made. 

Fingers crossed you get some good news soon.

Scott, if you happen to travel south at some point, I can check for fault codes for you.   Otherwise, there is also the option to take it to a dealer for diagnosis. 

Thanks for the offer 

Wow, that is an impressive mileage.  I wonder if anyone has a 220d with a similar or higher mileage?

Really want to have a look inside my intake now.  Mine has got 115,000 miles on it, so I am sure there is some crap in there.  I did try looking with an endoscope when I took my EGR valve off, but the head of the scope wouldn't go round the corner down the EGR hole.

Incidentally, there is another thread on here about carbon buildup on the back of inlet valves.  So, in the interest of that thread, can I assume that the back of your valves was as badly gunked up as the rest of the intake?

Damn, that manifold is bad.  Funnily enough, I took off my EGR valve a couple of days ago to clean it and had a quick peak inside the intake.  Probably not as bad as yours, but there was definitely a certain amount of sludge.  Perhaps it should be part of the cleaning cycle along with the EGR valve.  Incidentally, in the 5000 miles since I last cleaned my EGR, it had quite a lot of carbon build up, even though I do mostly motorway miles.

As for the cold start, 5th injector won't fix it cause that is used only for DPF regen.

Sounds like not enough fuel is getting in.  Have you checked for leaks?  Also, does it start after you prime the system?

By the way, did you remove the manifold yourself?  Was just wondering how hard it is.

Someone correct me if I am wrong, but I am sure I read somewhere that if you claim under the warranty, you can no longer cancel it without paying the full fee?

Good news so far

Hopefully, this will solve your problems, and be an interesting tale for anyone else going through the same thing.

Fingers crossed the good news continues into tomorrow.

By the way, I don't think you have mentioned how many miles your car has done?

This what the manual shows:

Manual seats -

Electric seats -

Sounds hopeful.

Got my fingers crossed that this will solve the issue for you.