Fuel Filter and Car Dying

[Chris QTown]

Hey guys,

1991 Hilux Surf SSR-X 2.4l turbo diesel (automatic)

Got it back on the road after 3 months of it sitting there (i would run it every 1-2 weeks to ensure quality but not drive it) and now i have a problem.

Had it running on idle for 10 minutes and it shut down.
Wouldnt restart - figured the fuel guage was out of wack so put 10 litres in it and it started fine.
On the way home i filled up at BP and then it wouldnt start again.
Could keep it running if i kept my foot down and held the revs up.
Next day it starts fine, travel for 10 minutes, go into a shop, come back out and it wont start again.
Same thing - keep my foot on the gas and it will start up.

So - i figure its the fuel line, got a new fuel filter (the old one had a lot of gunk and looked grimey as) and installed it, primed it and eventually it started.
Took her round the block and moments later it died again.

INSERT ANGRY FACE

[Chris QTown]

im about to drain, drop and clean the fuel tank itself, all the hoses seem fine and i cant find anywhere that is cracked or loose for air to get in.

it will start with my foot down, when it drops to 800-1000 rpm it hangs there for 3 seconds then dies (presumably from lack of fuel).

i checked and cleaned the electronic air sensor that plugs into the air filter and ran the engine without the filter itself (as its a bit black) but no change.

is there any way i can check if the fuel pump is working correctly?

[Chris QTown]

OK GUYS !

Found the problem.... fuel lines are all good, it was my VACUUM LINES !@#$

Does anybody have a schematic or exploded view of the whole vacuum line set up? Nev i have your images and legend of a few but the way they all work together as a whole would be appreciated !

I now have to have one vacuum line disconnected for my idle to stay, however i cant use 4WD now (as its vacuum operated) and just have one line constantly sucking in outside air (with a filter on it just in case).

[Chris QTown]

UFO/VSV valves



4WD VSV's/lines



Are all of these around the right way? :/

[NiftyNev]

Need bigger pics. I am half blind and can't make out what is what with those.

Nev

[NiftyNev]

If you block the hose you have the filter on for now, you should get 4WD back. The vacuum lines to the ADD VSVs look ok but also depends on if they are connected correctly at the diff.

Nev

[Chris QTown]

Nev, which filter sorry?

The trucks 4WD was working fine but it started to take longer and longer to disengage, until finally it would lock into 4WD - and the only way to get it out was to blow down the vacuum line manually.

I found a tiny vacuum hose unplugged on the passenger side of the engine and once this was fixed the 4WD vsv lines had waaayyyyy more pressure to them, but now to get in or out of 4WD i have to unplug a line (from blue vsv to engage) then plug back in, then unplug a line (from orange vsv to disengage) then plug back in.

Both of the lines coming from the 4WD vsv's have air going the same way and i feel one should go the opposite way.

Would you be able to check yours for me Nev?

[Wolfracer]

Need bigger pics. I am half blind and can't make out what is what with those.

Nev

Try Ctrl +

[NiftyNev]

Nev, which filter sorry?

The one you said was sucking outside air. The vacuum pump will not work correctly if it can't create a vacuum.

Nev

[Chris QTown]

Yes, but if i do that, the car stalls and dies.

And here lies the problem... :/

[Chris QTown]

took it to mechanics the other day to see about a new grinding noise i hear when it first takes of and they said the front shaft to 4WD was spinning but luckily wasnt connected to the hubs.
they had to disengage it manually with direct power to the 4WD motor on the transfer case.

man this thing has me so stumped.....

i have to manually blow into the actuator lines to engage/disengage 4WD and i have to leave the vacuum system sucking in outside air permanently with a hose disconnected in order for the truck to run.
if i reconnect the hose and seal the vacuum lines the truck stalls and dies after 1-2 minutes.

what on earth could this be ?????

[muddle]

Do the mod that removes the vacuum part of the 4wd operation, take off art the associated vac stuff and see how it is then.

[Chris QTown]

hey muddle, yeah i disconnected the 2 lines going onto the gold UFO EGR thingy and blocked them up with 2 inch nails (i dont have ball bearings), then reconnected the vacuum line that i had off so now the circuit is "complete".

no change...

i remember when i used to click her into 4WD there would be quite a loud electronic noise: "tttttzzzzzaaaap!" immediately followed by another electronic "click-click-click-click" noise which sounded like it came from in behind the dash (unless i was hearing it through the bulkhead).
now it doesnt even do that so i will test the vsv's for power today and go from there.

any ideas on the noise?

[Chris QTown]

Bump

Hey folks, some time has passed and I'm not sure what to do. My mechanic said when he applied direct power to the transfer case it goes in and out of 4wd. But he couldn't help me as it was probably a job for a diff and tranny specialist.
I figure it must be an electrical problem between the transfer and the 4wd switch in the truck so I took it to an auto elec but he couldn't find anything wrong.
Now I'm stumped.

I currently have the vacuum line of the add open as when the circuit is complete the truck shuts down after a minute or so.

The auto elec said one of the vacuum solenoids (the red or blue one) is faulty and constantly drawing air.
But when he put a working one in and connected the lines again the truck still shut down.

The 4wd worked fine when I bought it but then it would take 50 meters to disconnect 4wd, then 100, then 500 then it just stayed in 4wd.

I really don't know what to do and don't want to take it to Toyota!
All hello would be appreciated!!!!!

[andyverran]

Thats bad news bud....a year without a fix.

Can you recap what the fault is and what youve done already (I did read the thread but it's a bit confusing for my little brain).

You have a running issue you've tracked to the vac lines...did you find a diagram for the vac circuit? There is one floating around as I'm sure I've seen it posted on here...

There is a chance I have some vac bits in the garage for the 2.4...should that be any use...