Nissan patrol 4.2 engine .

Submitted: Tuesday, Oct 14, 2025 at 17:41
ThreadID: 151724 Views:2301 Replies:8 FollowUps:7
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Hi . Have a 2003 GU Y61 4.2 with 400,000 kms .... mostly dragging 3.5 tonnes of van around Oz . At around 2000 revs.... any gear .... not under load ... it coughs and runs terribly . Just had the fuel pump rebuilt , no change at all ....Injectors are a couple of years old and don't think it is them . Any ideas where I would look next would be greatly appreciated .Mark.
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Reply By: RMD - Tuesday, Oct 14, 2025 at 19:46

Tuesday, Oct 14, 2025 at 19:46
G'day Mark.
These might seem strange but perhaps.
1. The cam may have a worn lobe and at 2000 rpm, approx, there would be less valve opening and the subsequent intake airwave may be vastly lessened reduced/stuffed up & causing roughness around that rpm. Wave form travel does rely on quite a few conditions being met.
2. There could be a wire of the loom worn through or loose and it intermittently connects and reconnects at a particular rpm. It could also be a pump relay contact problem. Substitution of the pump relay may ID that.
3. With no load, the fuel line to pump may be an a slightly different position and a loose INTERNAL FLAP OF THE LINE, may flap and restrict fuel flow at certain revs. I found that on an old Fordson tractor years ago.
PS. I have spent a lifetime of diagnosing vehicles and do look for the NOT OBVIOUS reasons for problems.
AnswerID: 648604

Reply By: Gary T7 - Tuesday, Oct 14, 2025 at 23:43

Tuesday, Oct 14, 2025 at 23:43
You said only doing it around 2000 rpm .
May pay to check that nothing is blocking or restricting the air intake to the cylinders .
May be someone left rag in the intake . Seen that before.
Also check for air being sucked into the fuel system. cracked pipe lines etc, if air is getting in at revs it may not show as a leak.
Then check the exhaust system for blockages or restrictions.
Hard to diagnose without seeing and hearing it.
AnswerID: 648605

Follow Up By: RMD - Wednesday, Oct 15, 2025 at 19:25

Wednesday, Oct 15, 2025 at 19:25
Ifit runs ok at higher revs it is very unlikely to be a restricted exhaust!
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FollowupID: 930036

Reply By: Member - LeighW - Wednesday, Oct 15, 2025 at 08:44

Wednesday, Oct 15, 2025 at 08:44
Does not sound like an air issue if it's only doing it under light load and at one particular RPM.

Sounds like a fuel issue. Could be an injector but you say you had the injector pump rebuilt so sounds like you or someone suspects it may be faulty? I'm familiar with your model but a quick look at the net indicates that there is electronics inside your injector pump to control timing. It might be worth getting the injector pump looked at again to check that all is well in that area.
AnswerID: 648606

Reply By: axle - Wednesday, Oct 15, 2025 at 15:09

Wednesday, Oct 15, 2025 at 15:09
G/ Day Mark, Maybe the fuel cut off solenoid connection not so good ,wiring to that, or solenoid itself


.Cheers Axle
AnswerID: 648607

Follow Up By: RMD - Wednesday, Oct 15, 2025 at 19:19

Wednesday, Oct 15, 2025 at 19:19
Axle. Yes, I agree it is a possible , ie, connection issue at certain frequency of vibration.
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FollowupID: 930035

Reply By: Member - Happy Explorer - Thursday, Oct 16, 2025 at 07:20

Thursday, Oct 16, 2025 at 07:20
Hi Mark
I am assuming you got the fuel pump rebuilt because of this issue. That means the issue was preexisting, right? If so you can now rule out the fuel pump unless as has been suggested it is electrics within the pump that may not have been checked or tested. Could be worth asking the guys that rebuilt the pump about that. Also is it possible that the electrics are a separate module that can be swapped out at reasonable cost to rule that out or in.
Beyond that, did this problem start gradually over time or happen suddenly? If suddenly, can you associate the timing with any other event such as a service, other repair, some sort of unrelated damage etc?
Have you talked to a mechanic about it. Someone with good knowledge of older Nissans, not necessarily a Nissan dealer.
AnswerID: 648611

Follow Up By: boodah 11 - Thursday, Oct 16, 2025 at 10:10

Thursday, Oct 16, 2025 at 10:10
Hi guys .
The problem has been going for a couple of years ... very slight and intermittent at first and now more constant , hence the pump rebuild . Guys that did the pump have a very good name around my area . The pump rebuild fixed the smoke at start-up and improved fuel economy. I have worked through a few of your suggestions and am thinking it's a fuel supply issue . Coming down a long gentle hill at 100 - 110 ks and feathering accelerator to keep speed the same ... it " coughs and farts " and once you touch the accelerator, it evens out .
I'll replace fuel lines ... check the fuel primer for cracks and check out the electrics on the fuel pump . Might be worth a visit to the pump guys and talk to them as well .
It's fantastic how much help people volunteer on this site .
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FollowupID: 930037

Reply By: boodah 11 - Thursday, Oct 16, 2025 at 21:21

Thursday, Oct 16, 2025 at 21:21
Thanks to everyone for their advice and suggestions . Plenty to go through and hopefully find the issue .
AnswerID: 648613

Reply By: JohnnyC - Sunday, Oct 19, 2025 at 11:35

Sunday, Oct 19, 2025 at 11:35
Have a good look at the EGR system, make sure its not blocked, some engines rely on EGR air to run properly at low power, once you touch the pedal, it usually closes.
Also check that the inlet manifold is not choked up with sludge.
AnswerID: 648619

Follow Up By: RMD - Sunday, Oct 19, 2025 at 16:24

Sunday, Oct 19, 2025 at 16:24
JOHNNY
It isn't a COMMON RAIL DIESEL engine! EGR is NOT an AIR supply, it is HOT EXHAUST GAS.
Why will the intake be sludged up? with WHAT? CLEAN AIR?
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FollowupID: 930047

Follow Up By: JohnnyC - Monday, Oct 20, 2025 at 12:00

Monday, Oct 20, 2025 at 12:00
Every engine is required to direct any crankcase blowby into the engine intake manifold where it is burnt, instead of just venting it into the atmosphere.
Blowby is usually an oily mist which creates an oily film inside all of the air intake system, this in itself is not an issue.
Most engines also employ exhaust gas recirculation where, under certain operating conditions, exhaust gas is injected into the intake manifold to mix with intake air, the purpose is to reduce combustion temperatures and thereby reduce nitrous oxide emissions from the exhaust.
This is fine in theory but in practice the soot in the exhaust gas combines with the oil mist from the PCV and forms a thick sticky sludge in the inlet manifold and EGR valve, eventually this sludge hardens and can cause a restriction or blockage, this is a serious side effect of these two environmental control systems and the reason various EGR delete mods.
Normally the EGR valve is closed at idle and high power and only opens at low to medium power, if the ECU is programmed to run with EGR at these medium powers and there is none due to a blockage it can cause rough running, Boodahs Issue appears to be in this range hence my suggestion, especially as he said it is a high time engine.
Not too sure what RMD is on about, but I don’t think he’s a diesel mechanic.
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FollowupID: 930049

Follow Up By: RMD - Monday, Oct 20, 2025 at 15:05

Monday, Oct 20, 2025 at 15:05
JoHNNO
You said "some engines rely on the EGR AIR SUPPLY to run Properly. You Can't be a DIESEL MECHANIC, as ALL mechanics know there is NO AIR passing through the EGR valve on any ENGINE.
You also said 'Normally the EGR valve is closed at idle and high power and only opens at low to medium power, if the ECU is programmed to run with EGR at these medium powers and there is none due to a blockage it can cause rough running," How? explain How!
Diluting the incoming air charge with gas would cause less smooth running than MORE Air, ie normal, to more efficiently burn the injected fuel!
Was that from a GOOGLE SEARCH? It reads like it is!
What sensor is then sending the wrong signal to the ECU. it doesn't just act by itself!
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FollowupID: 930052

Reply By: Allan B (Sunshine Coast) - Sunday, Oct 19, 2025 at 18:42

Sunday, Oct 19, 2025 at 18:42
Mark,
First you had the "fuel Pump" (injector pump?) rebuilt, now you are considering replacing the fuel lines. What next? How far are you going to guess and spend $$$$ on what may be wrong without expert diagnosis? And listening to armchair mechanics guessing at what may be wrong.
Why don't you just cut to the chase and turn it over now to a good mechanic before spending more money and angst on it fruitlessly?
Cheers
Allan

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AnswerID: 648620

Follow Up By: RMD - Sunday, Oct 19, 2025 at 19:27

Sunday, Oct 19, 2025 at 19:27
Allan.
I agree about a decent assessment. However, some possibles mentioned are very unlikely. Time does degrade components but the diesel men to rebuild a pump and/or injectors are not overall diagnostic inclined.
Now realizing, after someone above mentioned timing control, that then means a TPS is present, and if over 400,000 km in much the same position of lighter load/cruise, the carbon track WILL BE WORN and likely not tracking as designed. The TPS would be the FIRST ITEM TO CHECK, or even simply replace because it cannot be very good and likely worn. That item will immediately correct the injection as it's Wiper clears the worn area as pedal is depressed or to idle.
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FollowupID: 930048

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