'89 FJ62 Won't Start and I'm looking for what else to check

[andrew.fletcher]

Quick background. Wife was driving the 62 yesterday, thought she smelled fuel for a couple of minutes but it went away. She drove it for about 40 minutes, parked it in the garage and it wouldn't start this morning. I can get it to start just fine with starter fluid but it won't stay running without it.
In order this is what I've checked so far following the FSM as much as possible:
-Fuel pump: Using the check connector I could hear the fuel pump but when I squeezed the fuel return line it didn't feel like there was any pressure in it.
-Fuel filter: had fuel in it but when I disconnected there was not a pressure release like I was expecting. Emptied it out and re-connected. Really need to change this since it has a little #1 with a big #89 on it (205k on the original filter, who knows)
-Spark plugs: gets spark no problem, need some adjusting though (let's get it running first!!)
-Fusible links: Continuity as per FSM
-Fuses: All good, none blown
-EFI Main Relay: Continuity as per FSM
-Circuit opening relay: Continuity as per FSM
-Cold start injector Time Switch: Continuity as per FSM
-Diagnostic code: #51 but the FSM confuses me with all the the possible issues with the a/c so I'm ignoring that for the time being. I don't believe they're related since I can get it to going with the starter fluid.
-Fuel in tank?: should have been the first thing to check just in case but I ignored the full reading of the gauge and rocked the truck back and forth to get the slosh of fuel sound going.
-Wiring connections in back: With the key in the on position there's no voltage going to the pump. Is there only voltage when trying to start/running?
-Hooked fuel pump directly to battery and it runs the same as with the check connector. I loosened the fuel pump side of the fuel filter fitting and got no fuel while it was hooked up. Rocked the truck again just to make sure I was hearing fuel!!

I did not check the cold start injector for pressure because I don't have the tools on hand to do that.

I'm at a loss of what to think and the only thing that comes to mind is something is clogging the fuel line somewhere or the pump itself is clogged inside the tank. Plan is check the line right outside the tank to see if it flows there. If not, then it's time to pull the tank off.

Did I miss something along the line? Is the fact that it starts with starter fluid sending me down the wrong path?

Just because the pump is making noise, could it still not be working or is there some kind of valve somewhere in the line that stopping the fuel from getting to the filter?

 

[cruiser88]

There is a wire for the fuel pump in the drivers rear quarter in the area where the rear washer fluid bag....or whatever its called. Fix that wire. I cannot remember the color of the wire now.

80 percent of the time when the fuel pump does not work that is the problem. You can bypass that crap altogether and run the pump to another power source. It does not need the fuel pump relay and it does not hurt the pump to run all the time when the rig is on.


But the simple fix is just to check that wiring.

 

[cruiser88]

Oh yea just for future reference you are right......just because you hear the pump that does not mean its pumping.


You can even wire the pump up backwards and it will still run....just not the truck.


Don't ask me how I know this.

 

[andrew.fletcher]

I hooked the two wires that are in the driver's rear quarter directly to the battery. w-b to negative, r-g to positive and I could hear the pump running. I took the fuel line off the filter while doing this and no fuel came out. That's why I'm at the point that it's either a clog in the line or the pump is bad even though it's running. Is it possible to reverse the wires and the pump still work going backwards?

 

[cruiser88]

I hooked the two wires that are in the driver's rear quarter directly to the battery. w-b to negative, r-g to positive and I could hear the pump running. I took the fuel line off the filter while doing this and no fuel came out. That's why I'm at the point that it's either a clog in the line or the pump is bad even though it's running. Is it possible to reverse the wires and the pump still work going backwards?

see my post above.


If you still don't get fuel with the wires hooked correctly...even if they are hooked directly to a 12 volt power source then you know whats next....filter,pump,sock or a line.

 

[andrew.fletcher]

I was afraid that it only ran one way but I should have taken the chance last night and swapped wires. I'll try that first later today and see what happens. If that works and I get fuel it's back to code #51 I guess. Just had another idea too. Gonna try blowing air in the fuel line and see if it's blockage. Anything to keep from dropping the tank.

 

[cruiser88]

I was afraid that it only ran one way but I should have taken the chance last night and swapped wires. I'll try that first later today and see what happens. If that works and I get fuel it's back to code #51 I guess. Just had another idea too. Gonna try blowing air in the fuel line and see if it's blockage. Anything to keep from dropping the tank.

You may want to clear the codes after you get the parts back together and before you start the truck. Simply just pull the EFI fuse for a few seconds.

 

[Ming89FJ62]

There is a wire for the fuel pump in the drivers rear quarter in the area where the rear washer fluid bag....or whatever its called. Fix that wire. I cannot remember the color of the wire now.

Yep, same thing happened to me several year ago.

 

[Randy88FJ62]

Oh yea just for future reference you are right......just because you hear the pump that does not mean its pumping.


You can even wire the pump up backwards and it will still run....just not the truck.


Don't ask me how I know this.

Experience is the best way to learn.

 

[Randy88FJ62]

You say the tank is almost full and she smelled gas when driving for awhile. Is there any way she topped off and filled it too high? This would get gas into the vapor lines on the passenger side rear quarter panel. Not sure if that would be causing the issue. I would need more input from someone who has troubleshooted that part. Just an idea to throw around.

 

[cruiser88]

Experience is the best way to learn.

Did you get your fuel tank patched up?

 

[andrew.fletcher]

You say the tank is almost full and she smelled gas when driving for awhile. Is there any way she topped off and filled it too high? This would get gas into the vapor lines on the passenger side rear quarter panel. Not sure if that would be causing the issue. I would need more input from someone who has troubleshooted that part. Just an idea to throw around.

I don't think so. She overfilled it about a year ago and got gas everywhere so she tends to underfill it now. I'll check the passenger side lines though too because the fuel smell is something that needs to be addressed once it's running again.

 

[Randy88FJ62]

Did you get your fuel tank patched up?

It's patched with gorilla glue and painters tape over that right now.

I bought some fuel tank epoxy to do it right.

 

[cruiser88]

It's patched with gorilla glue and painters tape over that right now.

I bought some fuel tank epoxy to do it right.

I was going to mention but I forgot.

I know you hate to hear this

drain the tank


drop the tank

take all the parts out


fill 3/4 with water


Silver solder the bad spot

 

[Randy88FJ62]

I was going to mention but I forgot.

I know you hate to hear this

drain the tank


drop the tank

take all the parts out


fill 3/4 with water


Silver solder the bad spot

I do hate to hear that. I find it ironic that the leak was created by me not wanting to drop the tank... (inside my head I'm like Chris Farley on SNL..)

 

[cruiser88]

I do hate to hear that. I find it ironic that the leak was created by me not wanting to drop the tank... (inside my head I'm like Chris Farley on SNL..)

I told you to be careful with the cut-off wheel




Oh hell we all screw up

 

[Randy88FJ62]

I think cutting the hold in the tank is my number one fxxx up. Since it had been drained and aired out for over 3 weeks I was safe. If I had done that the day of draining with vapors in there....
Number two was hooking battery up backwards. Who insulates the battery ground wire with red insulation!!!!

 

[Randy88FJ62]

Andrew, have you tried manually wiring the pump both ways to see if you can get it to start? If that doesn't work then i'm guessing clogged filter inside gas tank attached to filter or clogged lines somewhere to create low pressure.

I have noticed that my truck starts better if i leave it in the ignition position for a few seconds before cranking it to allow pressure to build up.
-Randy

 

[cruiser88]

I think cutting the hold in the tank is my number one fxxx up. Since it had been drained and aired out for over 3 weeks I was safe. If I had done that the day of draining with vapors in there....
Number two was hooking battery up backwards. Who insulates the battery ground wire with red insulation!!!!

Who done that?

I got my hands one time on 67 dodge van that someone burned up the whole wiring harness......I wired it up from scratch. ran like a champ afterwords.
Anyway....sorry for the hijack.

 

[Ming89FJ62]

One of the latest issues with the 62 was a strong gas smell and dripping fuel after a fill up plus a longer cranking than normal for start-up. Ended up being the nipple from the discharge of the fuel pump rusting out (damn Chicago road salt). Unfortunately, you need to drop the tank to check - but you're almost there anyway.