1998 Toyota Coaster bb50 electrical service manual needed urgently

[joseb90]

Hi guys/girls. Just joined from UK.

My Toyota Caetano (Spanish) coach conversion.

Engine will not run. No pressure at injectors. Pump is primed. So injector pump is cut-off, Had two mechanics look at it but without any success.

4.2l diesel 15B-FT engine. I have a Toyota engine manual specifically for this engine but need the "Toyota Electrical Wiring Diagrams Service Manual".

Despite contacting UK importer/ Toyota UK/ Toyota Europe I cannot get relevant technical information for vehicle.

So is there anyone out there with technical information who is prepared to share it with me.

I am geting desperate trying to get F...ing thing started.

Cheers to all.
J

 

[joseb90]

I need this version of Toyota manual but for BB50/BB58 chassis

 

[roscoFJ73]

Hi , are you sure thats the manual you need? On the landcruisers and other vehicles, the engine manual contains the engine electrical information.
The body chassis manual contains the rest of the electrical system. Maybe things have changed.
Have you tried a diesel injection shop, some of them have knowledge on how the computer controls the injection pump.
Ive seen a similar problem on other coasters and landcruisers and it was loose connectors.

Does the engine turn on the starter?

I put the service manual code "EWD172Y" into google and got a few manual download offers. They are usually under $10
But they are saying that code is for a 1993 model
If you dont get satisfaction I would try some of the Australian forums, this model is quite common here.

Nice looking bus by the way.

 

[joseb90]

Hi
Engine cranks but no pressure at injectors.
I have had zero success with downloads content.
I need Toyota electrical information for 1998 Coaster/Dyna chassis.
This predates Toyota's current on-line technical support so they do not recognise my VIN.
Does anyone know whereabouts Toyota locate serial no "plate" for identification on commercial vehicles.
I have been fighting this problem for weeks and it is totally doing my head in.
J

 

[roscoFJ73]

Does anyone know whereabouts Toyota locate serial no "plate" for identification on commercial vehicles.

Most Toyotas have an aluminium plate with information about the exact model somewhere in the engine bay

Does any of this look familiar in regards to the exact model you have? I think yours will be the BB50R-ZEMQW

 

[roscoFJ73]

Have you tried running a jumper lead from your batteries to the fuel cut solenoid on your injection pump? This will energise the solenoid and allow fuel into the pump. Toyota suggest to try this on some landcruiser diesels when you are stuck.
As the connection is made you should hear an audible click. Ive tried it and it works. I rigged up a switch and a wire into the cab and was able to drive and shutdown the engine when needed.
Another test is when you turn the key , you should hear the click from the injection pump solenoid.

 

[joseb90]

Well guys it is good to get some feedback.
Chassis is BB50R-ZRMRWW1
injector pump is ND 22100 5C350 ie older mechanical control injector pump not electronic control. 15B-ft rather than 15B-fte.
It does not have a conventional fuel cut-off solenoid. The only electrical connection is for tachometer drive (83180-36060)
There is lots of vacum piping connecting electrical valves- which I have checked out with a meter/seperate power supply.

90910-12162 vacum switching
17630-25010 assy, air control - which activates with ignition switched on
another I cannot identify

Toyota Europe Technical Support cannot recognise this vehicles UK VIN number, which seems fantastical but heh.

So I am still looking for Electrical Wiring diagrams and also ideally some explaination of how it's older mechanically controlled injection pump can be diagnosed.

Bear in mind engine is between front seats , accessed from above, with very limitted access. I cannot even see the injector pump underneath inlet manifold.

Cheers
J

 

[roscoFJ73]

These are pics of your injection pump based on the part number 22100 5C350 . I havent seen one of these before, although its an inline pump, it looks a lot different to the older style used on the H and B engines from the 70s and 80s.

 

[roscoFJ73]

As you can plainly see, its a Euro model. But because its an incomplete vehicle ( Caetano buys them that way to build onto the chassis) it maybe that Toyota UK is refusing to recognise the vin.
Another way might be to give them a vin from a model with an identical engine that they do recognise. This one is a non caetano model JTB43BB50
They are being bastards because Toyota Australia will sell you parts for grey imports they have in stock for Australian models.
I would also try a fuel injection specialist, they can usually get access to the specs via Denso, the manufacturer of the pump. You can also contact Denso distributors direct.
Have you tried contacting Caetano for help?

 

[joseb90]

Thanks for the pictures, they confirm what I have already found out.
Caetano Portugal are being uncoperative. In fact they are conducting a witch hunt with Caetano UK for their lack of help.
Toyota UK recognise VIN ( 17 digit number) but have limited information. Toyota Europe claim it is not a European model despite being built at their plant in Portugal.
As usual in any collaboration given any problems one party blames the other.
I think my last hope is Nippon Denso as you suggest.

 

[roscoFJ73]

I dont think this is a big job for any proper diesel injection shop. There is a vacuum diaphragm connected to a lever. Its called the "ACUATOR, FUEL CUT" I think if you could apply vacuum to that, it would start. Im just a little confused how an engine would have vacuum on start up. I dont know if the starter would spin the engine fast enough to create vacuum via the vac pump at the front of the engine. But maybe it does or maybe the vacuum canister would store enough vacuum to activate it. It would probably also start by pulling it back manually. You maybe able to attach a pull wire and run it into the cab.
These vacuum diapragms usually have an electric solenoid that opens or closes off the vacuum. The aircon fast idle and the transfer case 4wd on some landcruisers work this way.

 

[joseb90]

Well Nippon Denso service agent cannot give me diagram for exterior of pump.
However from what I can tell looking at photo of my version of injector pump - it has a dome attached to a rod actuating a lever on side of actual pump.
So you are spot on.
However I cannot find a more expanded version of your drawing using partcode.
I have tried pushing rod whilst cranking engine - no start.
Maybe if I tee into line with my portable vacum pump that might work somehow.
You guys have been more use than Toyot/Caetano combined.
J

 

[ozcrusier]

When you try to start engine does this rod shuffle around stopping in a different location to ignition off. If not disconnect rod and try starting in the three locations it should have. Off, prime, run.

 

[ozcrusier]

Also the engine won’t turn off with key you need to stall engine or use the rod on pump. Some Toyota pumps have a lever as well to stall engine.

 

[roscoFJ73]

Looks like this actuator replaced the old EDIC used on the 3B and 2H

Maybe if I tee into line with my portable vacum pump that might work somehow.

Its worth a try but if you cant start it by moving it with your hand , its unlikely it will work with vacuum moving it. Have you tried removing an injector line from the delivery valve (pump end) and see if it can pump fuel out of there. Im just wondering if your injector lines are full of air.

 

[joseb90]

Given I have absolutely minimal access to pumpI have actually managed to shift lever at actuator end and tie-wrap in on position. Don't know if vacum is working so bypass it. Pressumably vacum comes from brake assistance pump.
Briefly tried cranking engine - no joy. Is the pump now airlocked having been repeatedly trying to start with cut-off activated?
Tomorrow my plan is -
Try cranking whist pumping primer.
Try cracking lines at injectors to see if any fuel whilst cranking ie purge lines.
Try some easy start and get engine spinning, though realistically unlikely to be faster than cranking over.
Utube has a method of sucking fuel through by using fuel return line. Not sure if I have similar but sounds interesting. though how to access this?
Otherwise third mechanic to call out, allegedly this one has worked on them before = £60/hour + travelling. Sounds like desperation.
J

 

[roscoFJ73]

Is the pump now airlocked having been repeatedly trying to start with cut-off activated?
Tomorrow my plan is -

Could be . Making sure there is fuel in the injector lines is the first thing that should be done.

Pressumably vacum comes from brake assistance pump.

There is a vacuum canister, about the size of a large coffee mug and painted black , that supplies vacuum to all the components that need it.
Its usually in the engine bay , near the brake booster

 

[roscoFJ73]

Does it have glow plugs? If you remove the glow plugs , you can spin it really fast on the starter. This will pull the fuel through (if the actuator is allowing it) and you will see small plumes of fuel exit the glow plug hole. Then you replace the glow plugs and it should start immediately.

 

[joseb90]

Still refuses to start! I am loosing the plot over this.
Fastened injector cut-off actuator in on position and slackened of injector pipes.
Cranked engine whilst frantically pumping fuel primer. Still no fuel at injectors.
Is it possible that cut-off has jammed internally within injector pump due to lack of use whilst parked up? It started a month before.
Which is more likely injector pump or vacum pump failure?
Mechanic who knew engine has retired and re-located so now I am stuffed.

 

[Torevo7]

Can anyone give me ecu wiring diagram of 15b fte please