Replaced Injection Pump Top Cover Gasket- Now Truck Won't Start

[binnquiddle]

Hello,

I have a 1992 JDM LN106 Hilux with the 3L. It has just over 200k miles, hasn't given me many issues. It sat for a few months, and when I went to start it next, was leaking a ton of diesel from the injection pump top cover gasket. No problem, I ordered the replacement gasket and went to swap it. Just before I dug into the pump I verified that it started and ran, even if leaking fuel. After priming the hand pump it started up no problem.

When taking the top cover off of the pump, I did not scribe the position of the pump throttle shaft where it meets the linkage. I looked in the 3L repair manual and set it to the scribe marks as shown. Installed the new gasket and a new O ring seal on throttle shaft, put it all back together. Now- I just get cranking and no start, or even an effort to start.

My assumption is that when I reinstalled the throttle linkage, I put it on the wrong spline. I cracked the 17mm banjo and bled the low pressure side with the hand primer, verifying I'm getting fuel into the pump at least. From there I cracked the injectors and cranked, but got no fuel at all to any of them.

Any insight from anyone on this?

Thanks

 

[TheBussman]

does the solenoid click when you turn the key on?

 

[binnquiddle]

does the solenoid click when you turn the key on?

I hear a solenoid when the key is turned but it doesn’t sound like it’s the spill valve one. More of a thunk up by the relays. If i plug unplug/replug the spill valve solenoid while the key is on i hear a click in the pump.

 

[gnob]

pretty sure if you aren't getting fuel at the pipes, it's the solenoid.

have you tried using the cold start cable or just pedaling it to try to start ?

 

[binnquiddle]

pretty sure if you aren't getting fuel at the pipes, it's the solenoid.

have you tried using the cold start cable or just pedaling it to try to start ?

I have tried no throttle, throttle to the floor, and everything in between- never any fuel spray from injectors regardless of what i do with the pedal

 

[binnquiddle]

does the solenoid click when you turn the key on?

Solenoid is getting 12v with ignition on and clicks when the voltage is applied

 

[TheBussman]

I have seen one that did click but the solenoid was still bad, wouldn't move the plunger. I'm pretty sure even if your throttle shaft was in the wrong spot then it would still start. try tapping on it while somebody else turn the key on and off, then try again. if it still doesn't work remove the solenoid and crank. you can plug it back in and connect a ground test lead. and watch the solenoid plunger it should move when the key is turned on and off, and there should be fuel flowing out of the hole when cranking, would make a big mess don't put your eyes right above it while cranking. if the is no fuel then your drawing air in instead of fuel or you have a clogg, hoses routed wrong or something else.

 

[binnquiddle]

I have seen one that did click but the solenoid was still bad, wouldn't move the plunger. I'm pretty sure even if your throttle shaft was in the wrong spot then it would still start. try tapping on it while somebody else turn the key on and off, then try again. if it still doesn't work remove the solenoid and crank. you can plug it back in and connect a ground test lead. and watch the solenoid plunger it should move when the key is turned on and off, and there should be fuel flowing out of the hole when cranking, would make a big mess don't put your eyes right above it while cranking. if the is no fuel then your drawing air in instead of fuel or you have a clogg, hoses routed wrong or something else.

Finally had time to look a little more today and tried the following:

- Verified correct hose routing
- Pulled solenoid from truck and verified plunger was operational.
- Cranked without solenoid installed. There was fuel coming out of the solenoid hole, but not high pressure. It was flowing out when cranking, but not spraying or anything like that.
- Reinstalled solenoid without plunger to remove it from the equation.
- Cranked more, still no fuel to injectors.

I'm at a bit of a loss, it seems at this point the only other point of the fuel path to check would be from the BOTTOM of the hardlines on the pump side. Especially given the truck started right up before I touched it, I'm worried I screwed the pump somehow but with only the top cover off that seems unlikely.