Cummins 4bt into my FJ60

[Wyoming]

NO JOY!
Well, everything was hooked up last night, all fluids were added. It was time to see what the beast did. It spun right over with the starter...then it didn't. Hmmm...It would click like the bendix was trying to engage, but something was preventing it from turning. We started to diagnose and quickly got to the fuel shut off solonoid. Something was wrong. The wires coming out of the solonoid are red, black and white. The wires on the wiring harness are red, black and blue. Therefore, red should go to red, black should go to black and white should go to blue, you would think. Turns out, black went to black, red went to blue, and white wen to red. go figure. So that was fixed, but the solonoid was still very hot, so I had to disconnect it from the starter to get the starter to fire. Now the engine was rolling over just fine. The hold on the solonoid was engaged and we were just waiting for the system to get fuel and that first fire. That's when I saw it: Fuel on top of the injection pump!...Nooooooooooo!
See the injection line to the left? Right below the top nut that holds the injection line on is somthing that looks like a 24 point+ collar. That collar is on top of a column that goes down to the injection pump and has a nut at the base on each side (one you can see, the other behind) that secures a keeper for the column. The leak is right between the keeper held on by the nut and the culumn.
Now, I'm looking for a service manual for the Bosch p7100 injection pump, a list of the specialized tools that I need to fix the leak and possibly, if worse comes to worse, rebuild the darn thing. Any knowledge would be appreciated.

I also tweaked the fuel linkage by bending the little plate that is connected to the fuel pump that the linkage screws into, shortening the haight of the pedal, reaming out the pedal side of the linkage with a drill and rmoving one of the return springs. It works much nicer now.

 

[The Phoenician]

Sorry to hear that brother. I made sure to turn on my engine while I was back home before starting the swap specifically to avoid this kind of set back. I'm sure in the end it will be a simple explanation and we'll all learn from it. I like what you did with the pedal. Keep posting, it's one of the few things that brings me joy out here.

 

[Wyoming]

Okay, I talked to the two main diesel mechanics in town and one over the pass and none of them will work on a P7100. No one has the tool I need to remove the delivery valve holder, and the socket costs...wait for it...$260! I'll take two please. And the guys said they don't work on them because they can never get them back together correctly. So, what are the chances I could, armed with and overpriced socket and good intentions?

I'm going to have take the pump off the rig I just got back together and send it to Gillette Diesel in Utah and have them take care of it. From what I understand they are a quality outfit. If I wasn't in a hurry, I would send it to Cullman, but I could have this thing back by the end of next week if I get it in the mail tomorrow.

 

[davegonz]

Sorry to hear about the IP issues you are having.

 

[cullmancruiser]

NO JOY!
Well, everything was hooked up last night, all fluids were added. It was time to see what the beast did. It spun right over with the starter...then it didn't. Hmmm...It would click like the bendix was trying to enguage, but something was preventing it from turning. We started to diagnose and quickly got to the fuel shut off solonoid. Something was wrong. The wires coming out of the solonoid are red, black and white. The wires on the wiring harness are red, black and blue. Therefore, red should go to red, black should go to black and white should go to blue, you would think. Turns out, black went to black, red went to blue, and white wen to red. go figure. So that was fixed, but the solonoid was still very hot, so I had to disconnect it from the starter to get the starter to fire. Now the engine was rolling over just fine. The hold on the solonoid was engaged and we were just waiting for the system to get fuel and that first fire. That's when I saw it: Fuel on top of the injection pump!...Nooooooooooo!
See the injection line to the left? Right below the top nut that holds the injection line on is somthing that looks like a 24 point+ collar. That collar is on top of a column that goes down to the injection pump and has a nut at the base on each side (one you can see, the other behind) that secures a keeper for the column. The leak is right between the keeper held on by the nut and the culumn.
Now, I'm looking for a service manual for the Bosch p7100 injection pump, a list of the specialized tools that I need to fix the leak and possibly, if worse comes to worse, rebuild the darn thing. Any knowledge would be appreciated.

I also tweaked the fuel linkage by bending the little plate that is connected to the fuel pump that the linkage screws into, shortening the haight of the pedal, reaming out the pedal side of the linkage with a drill and rmoving one of the return springs. It works much nicer now.

If you're lucky it's just some bad o-rings causing your leak. If your luck is anything like mine the barrel is cracked or the pump housing is eroded . If it turns out to be an eroded pump housing let me know, we can repair that much cheaper than what a new pump housing would cost. I feel your pain, it seemed like it was one unexpected expense after another when I was doing my conversion.

 

[Wyoming]

If you're lucky it's just some bad o-rings causing your leak. If your luck is anything like mine the barrel is cracked or the pump housing is eroded . If it turns out to be an eroded pump housing let me know, we can repair that much cheaper than what a new pump housing would cost. I feel your pain, it seemed like it was one unexpected expense after another when I was doing my conversion.

At the end there, everything was fighting me tooth and nail. It got to the point that if something went right or the way I planned, that's when I got nervous because I knew there was a massive ****-up coming.

At some point you breath a sigh of relief because everything that can go wrong has, and there is nothing left.

 

[disassociative]

At some point you breath a sigh of relief because everything that can go wrong has, and there is nothing left.

Love the attitude, not to mention the grit. Sorry about your luck, no doubt we'll all get to learn something from it.

 

[Wyoming]

Love the attitude, not to mention the grit. Sorry about your luck, no doubt we'll all get to learn something from it.

I should knock on wood because it's tempting fate to say nothing else can go wrong. But, I was knotted up worrying about the injection pump and whether or not I was going to have to part with more cash. Now I know.

The tracking number says the pump is at the shop in Utah. Just waiting for the call.

 

[GLTHFJ60]

s***ty luck my friend, but at least the pump is in good hands, ready to get fixed.

Are you having them tune the pump while it's at the shop?

 

[Wyoming]

Are you having them tune the pump while it's at the shop?

Oh yes, the guy is going to bump the timing a little and calibrate it and the whole shabang. While I'm not happy about parting with more cash, I am glad to have the darn thing 100% taken care of and what I want. Now I know it won't go bad on a trip to Salt Lake City, or somewhere else.

 

[Wyoming]

Just got the call from Gillett. They are not cheap. Rebuild, springs, fuel plate, gsaskets, etc...wait for it...$1380. That hurts. Time to get back to two jobs.

Just glad it didn't go wrong in the middle of Nebraska.

I did take the opportunity to make sure that the truck really runs like I want it to. It should put out 175 horsepower and 400 ft/lbs of torque. I think this should fit me just right.

 

[isbj60]

Just got the call from Gillett. They are not cheap. Rebuild, springs, fuel plate, gsaskets, etc...wait for it...$1380. That hurts. Time to get back to two jobs.

Just glad it didn't go wrong in the middle of Nebraska.

I did take the opportunity to make sure that the truck really runs like I want it to. It should put out 175 horsepower and 400 ft/lbs of torque. I think this should fit me just right.

I think you are really going to love those numbers. My 3500# diesel jetta only has 100/177 hp/tq, and it is not lacking for power. It's no rocket, but it always responds to a dip into the throttle, which is pretty neat.

 

[Wyoming]

the injection pump should be here on Wednesday. Everyone cross your fingers and knock on wood.

 

[Wyoming]

The heavens opened and the angels sung...

The injection pump is back. I will attempt to install it and get the rig started tonight depending on shop availibility. Again, fingers and wood.

I have not gotten to open the box it came in yet, so I don't even know how it looks. I'm guessing the same.

 

[Wyoming]

Nope, I guessed wrong. That !@#$% thing is black. Which is now the color it is going in as! I am not painting that !@#$% thing again!

Other than that, it looks beautiful.

 

[Wyoming]

So, here is the rebuilt injection pump. I'm in contact with Lloyds of London to have it insured. And, here is the whole project back to where it was two weeks ago. Everything is buttoned up and ready to go to try and start it tonight.

 

[The Phoenician]

That color looks really nice with the engine block.

 

[Wyoming]

That color looks really nice with the engine block.

Thanks. Yeah, it doesn't look bad. Where are the new pictures of your rig?

 

[The Phoenician]

I should have some this week. Mine is not a rush job, since I'm stuck in Iraq for some time, so the pics are slow to come by. Edwin works on it on the side when he has time. As long as it's ready by the time I'm home, I can deal with the slow pics and progress.

 

[GLTHFJ60]

It's becoming more assembled, and that's always a good thing. Good luck on getting it fired tonight! Make sure to take video