KZN185 Cut out & won't restart

[bryanisaoldgit]

theres a small jumper pin in the fitting in engine bay you have to take that out
an put it back after
i know this may sound daft but you did turn ign on

[the silver surfer]

I saw that little jumper pin in the bottome right but didn't touch it as the instructions from that link never mentioned it! B***S!!! Back down there again in the morning then

As far as the other parts of the process goes I followed to a tee, turning ignition on when necessary! lol

Do you happen to know where the secondary diagnostic plug is inside the cabin?

Also, I really appreciate you making the effort to help Bryan, thank you.

[bryanisaoldgit]

i got the same motor and as far as i know there is no second plug and i have
had most of it apart just cause i like playing wid it
before you do any more disconnect the batt for at least 20 mins that will reset
the ecu
try starting if no go then try codes

[the silver surfer]

You don't think it's worth taking the jumper pin out and trying that first, then do the battery disconnect and then try again?

[bryanisaoldgit]

thing is if you take batt off first it will clear any codes stored
so when you try to start it if it won't go it will only show code
of whats wrong

[the silver surfer]

Great thinking Batman! Will report back tomorrow.

[the silver surfer]

Hmmmpf, sweet fa, nada, ziltch. No flashing lights, nothing at the volt metre just still turning over with the fuel/water warning light on full time.

I did go down to the Bosch/Denso diesel specialist to check his diagnostic kit out but low and behold he does not have the Surf info in his kit either, although he does have the 22 pin cable.

So rather than pay for a tow truck to take the car down to him and then bring it back I'm thinking that taking the fuel pump off and just getting him to servie that could be the most logical option? Any thoughts Bryan?

Update;
I went back down there again after reading some more posts on here about similar sounding problems and checked the voltage at the Spill Valve (solenoid?) on the Diesel Injection Pump. Once I finally got the prongs in the connector holes I was getting 3V and climbing. So with that now discovered do you think it's a good idea to get the pump off and down to the Injector Guru?

[bryanisaoldgit]

have you cleaned the fuel filter

[the silver surfer]

Yes, as per my original post, I replaced it about 6-7 weeks ago. I've ordered another new one as I was never happy with the one I got from the shop, it was a bit on the tall side (MANN) and the drain plug is well snug onto the bodywork. In any case I've asked the mechanic to take the injector pump off, which I'll take to get cleaned and serviced and at least it will rule that out. I'll put the new filter on next week and see how we get on from there. I'm also going to buy a new fuel filter drain plug and lead, what the worst that can happen doing that!

[charvell]

Yes, as per my original post, I replaced it about 6-7 weeks ago. I've ordered another new one as I was never happy with the one I got from the shop, it was a bit on the tall side (MANN) and the drain plug is well snug onto the bodywork. In any case I've asked the mechanic to take the injector pump off, which I'll take to get cleaned and serviced and at least it will rule that out. I'll put the new filter on next week and see how we get on from there. I'm also going to buy a new fuel filter drain plug and lead, what the worst that can happen doing that!

You need to make sure there is no air getting into the fuel system, start with the simple stuff the fuel filter has a rubber washer you need to make sure it is on correctly, how do you know there is no water in the fuel? that is what the light is telling you.
Check to make sure that the primer goes hard when you pump it. Open the filler cap and listen for air escaping. What fuel are you running on?

[the silver surfer]

Thanks for your reply charvell. Running on 100% normal white diesel at the moment and have been for a few months.

I thought the fuel filter was an option, but quite a bit of time has passed since I changed it, otherwise it would definitely be a little more than coincidental. I don't know 100% that there's no water in the fuel, but when I took the filter off to check it when it first refused to start it all looked good, one single liquid component, nothing in the fuel mix at all.

Just out of interest, is it possible there's air between the filter and the injectors? If so and it was actually caused by the fuel filter seal not being 100%, how would I irradicate that? Would simply getting a good seal on the filter sort it?

[charvell]

Thanks for your reply charvell. Running on 100% normal white diesel at the moment and have been for a few months.

I thought the fuel filter was an option, but quite a bit of time has passed since I changed it, otherwise it would definitely be a little more than coincidental. I don't know 100% that there's no water in the fuel, but when I took the filter off to check it when it first refused to start it all looked good, one single liquid component, nothing in the fuel mix at all.

Just out of interest, is it possible there's air between the filter and the injectors? If so and it was actually caused by the fuel filter seal not being 100%, how would I irradicate that? Would simply getting a good seal on the filter sort it?

Make sure that the rubber seal that sits on the thread of the filter where it joins the primer is in place. have you tried bleeding the injectors? you also need to check the primer to see if it goes hard when you prime it.

[kamaangir]

These trucks are old school diesel technology, any half decent diesel fitter can diagnose problems with it. If its not starting fuel starvation could be the issue, crack off the nut on the fuel feed pipe to injector 1, crank engine over and see if any fuel spills out the loose nut. If yes tighten and do the next one. If no then work your way back to the tank. You can rig up a small bottle of diesel directly to the pump, by passing the filter and the tank, see if it starts. If it does and runs ok, you work your way back till you find the problem.

If none of that works it may be the pump.

[the silver surfer]

Thanks for replies guys, going to pop down there shortly to have another look.

The primer does go rock hard after about 4 or 5 pumps, but I will check the seals again. When my new filter arrives next week I'll swap that over too just to be sure.

Taking the injector nuts is a good idea, if he hasn't already removed the pump I'll get him to do that first.

Missing my truck big time!

[the silver surfer]

Well the mechanic had already looked to see if there was fuel at the injectors, there was not. There's fuel upto the pump, but not through it! I'd say that was fairly conclusive that there's an injector pump problem.
The pump should be removed on Monday and I'll take it to the specialist to sort, I'll report back when there's more news.