Fuel Filter and Car Dying

[Chris QTown]

Hey mate,
Well when I bought the car the 4wd worked.
Then all of a sudden it took longer and longer to disengage before finally just staying in 4wd.
My mechanic had to apply direct power to the transfer case to get it out of 4wd.
I later found a vacuum line unplugged but I suspect this was always unplugged because when I reconnected it, the truck would shudder and die after a minute.
It sounds like an electrical problem to me but my slack auto electrician couldn't find anything wrong with it and it had him boggled.
I bought 2 2nd hand vacuum solenoids and installed them but so knows if they are working, apparently one of them is constantly drawing air.

[andyverran]

Well...best start here then I guess...
Hopefully one of those will help you...

I'm certainly no expert on the vac system, but a disconnected vac line rather suggests a leak that has been bodged around and not fixed.
..so leaking pipes or knackered valves would be my starting point...
I know you have done some of this already, but would probably be worth trying to forget everything to date and start a fresh.

So I would:

Check every pipe for cracks and splits (wiggle them about a bit)
Check the routing is correct...including the disconnected one.
I don't imediately know how you would test the valves...but someone will!
...see what can be learnt from that.

[andyverran]

This one might be handy too, nice and clear....

[Chris QTown]

Thanks for the diagrams, ill have another look and see what's what.
I heard somewhere that if the diff has no oil it won't operate into 4wd either, something to do with the sensor!?!

[Chris QTown]

Also do you know where the 4wd fuse is?

[andyverran]

Also do you know where the 4wd fuse is?

Not a clue bud....looks like it's 20A, might help you find it.

Found this (for the 3.0L) but has a nice diagram of the VSV opperation if you scrol down a bit...
http://dahn.webcity.com.au/~toy49040...455&view=print

As to diff oil...I pass....Bushwacker is probably the guy to ask...there is a wiring loom to the front diff but that's the sum total of what I know about that.

Pic may come in handy in the future...

[andyverran]

You may also want to eliminate the ADD in the future, see this thread:http://www.hiluxsurf.co.uk/showthread.php?t=66755

[Chris QTown]

Yeah I saw that post a while ago and id love to convert to manual hubs but am saving for a house atm and don't have the money blah blah blah...
Thanks for that relay diag I thought it may be behind the dash, I'm just so puzzled... If it was a simple electric fault then it would have stopped straight away, but because it faded gradually I'm more inclined to think it's mechanical or vacuum.
So I'll go over all the vacuum lines and buy new solenoids to start with.

[andyverran]

Yeah I saw that post a while ago and id love to convert to manual hubs but am saving for a house atm and don't have the money blah blah blah...
Thanks for that relay diag I thought it may be behind the dash, I'm just so puzzled... If it was a simple electric fault then it would have stopped straight away, but because it faded gradually I'm more inclined to think it's mechanical or vacuum.
So I'll go over all the vacuum lines and buy new solenoids to start with.

If mine ever plays up I'll just remove the ADD...you don't need free wheeling hubs, they're just a little more efficient fuel wise...and I don't do enough miles to care these days.

The fact that you have a vac pipe already off when you got the car makes me think it's not electric...

If you weren't on the other side of the planet I'd say pop round and borrow my spares...hay ho, such is life.

[Chris QTown]

http://imageshack.com/a/img809/961/9gla.jpg

The vacuum system is disconnected at the T piece.
If I plug it back in or put my finger over the vacuum hose (on the right) the car dies immediately.

Does the add system need to be constantly drawing air?
And why would this stop the engine!?!?

[andyverran]

Frankly, I don't know....but if the vacuum has to leak for the car to run something is very wrong.
These have a throttle butterfly and a little popet valve type gizmo in the throttle body, does stuff with egr, provides air at idle to I think and closes when you turn the engine off....perhaps the vacuum side is fine and is hiding something wrong there.

Consider taking a look there.

[Chris QTown]

http://imageshack.com/a/img42/6929/msfn.jpg

The T piece connects thru to the line on the left next to the air intake pipe.

[Chris QTown]

I'd love to see pics of someone's set up to see if mine has something wrong there...
What /how would I check the butterfly valve?
Is that the gold UFO looking thingy?

[andyverran]

I was just looking for pics of my old one, but I seem to have mostly just the parts as I took them off, I'll dig up my video and see if that's got anything on it that's of use...though the manifold and throttle is still in the garage so I could look at it in a week or so (working till then) if you have no joy before hand...

[andyverran]

ok, this is mine running, induction pipe shoved out of that way....maybe you can see something of use....the pipe you have disconnected is visible but I can't quite make out where it goes..

https://www.dropbox.com/s/9hid6r9f95...duff_turbo.mp4

Thread on the EGR here:
http://www.hiluxsurf.co.uk/showthread.php?t=36864

Funcky symbolic diagram of the EGR circuit on NiftyNevs post part way down...