[royce]

find the fuel pump relay and bridge the power supply and pump terminals and the pump will run all day long with the key off

[89_tintop]

first off... get hold of a decent fuel pressure gauge and check it properly. inline with a t piece.
you need to confirm what pressure you are getting..

have you done a compression test??

[gman]

keep at it scales you'll get there

[royce]

I reckon you need to check the dead head pressure, so the gauge straight in the line, no reg or anything

if its low the pump is stuffed or there is a leak, if its high you have a flow restriction

[Scales]

thats what ive been doing. unplugged hose from fuel rail, connected straight to guage.

just rang the local "bosch" dealer. 145inc gst. for the fuel pump.

[Moag]

So if you disconnect the vacuum hose while running the fuel rail pressure should increase slightly (5 -10 psi) ?

[Scales]

nope. not in the slightest. disconnect vac line and no change. in fact the return line has been disconnected for some time, with no fuel running back to tank.
theres not enough fuel pressure to overcome the spring pressure of the reg.

the only change happening when i disc the vac line is that the rpm goes up SLIGHTLY due to the vac leak created. block the hole with my finger and it goes back to the way it was when it was connected.

[Moag]

So reg possibly ok.

Still think it may be your filter

[Scales]

nice pics dude, your a champ at them!

im trying to devise a way of delivering fuel without the use of any of the fuel pump or filter, or even the lines for that matter. that way i can rule the engine side out.

i dont want to just assume its the 300 dollar filter...

wouldnt mind gutting it, but dont have the stones to do that.

[Moag]

No assumptions needed.

With pump out the tenth time, some tubing, your gauge (or a bucket) and some add on wiring there should be a way of testing the filter and then the pump.

Try not to burn though.

[Scales]

yeah i thought about trying that. i might just put the pump in a bucket and hook it up to a spare car battery.

[royce]

do that, with it pumping directly into your gauge with no lines or bypass, see if you get a higher pressure

to try without the filter run hose from the pump outlet to the fuel line under the car and start it up

[Scales]

FIXED IT!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!



Celebrations WOOOHOO!!!!

had to set myself on fire to find out though..... luckily only a small flame and had hose on hand in case. must of had a tiny spark everything was sealed up, oh well. anyway, on with the problem.

I took the tank back out (getting good at it now) and put the whole assy in a bucket with some fuel. put the pressure guage on the outlet and wired it up ready to pump fuel. when it was all ready to rock, started the pump up and it made some small pressure in the guage and then started pissing fuel out of the area circled



so i pulled out that part and theres just a small o-ring and a post assembly in there, the o-ring wasnt seated right (sick of these things) so put it back on the post and shoved it back in.

powered it up again, MASSIVE pressure. (thats when the fire happened lol) so put the flames out, put it back in the car temp fit style and primed the line. straight away fuel came out of the fuel reg return line, so i closed that up (obvious to me now pressure was sufficient)

Started the engine, AND WOOOOHOOOO!!!! shes sweet.

now i just gotta put it back together, this may take a while lol

[atari4x4]

[tim80z]

atari4x4 wrote:

x2


You must be an expert in Jimny fuel systems by now.

- Tim.

[Scales]

yep im all over this shit now. ive got so much shit to put back together now, then i can start pulling panels off to get the bulldust off this beast.

[Moag]

Cooool - Shepped it

[Scales]

whats this shepped thing?

anyways, time to theorize.... I was looking at some vids of the trip last night and noticed that the first time it was hard to start was as i was crossing the Pascoe river, was a fairly deep crossing. after i made it over, i stalled it... not sure if it was me or the pump, either way.... it took about 4 or 5 goes to get the engine started again, and it happened again on the climb out of the pascoe.

after that it was pretty much ok, until i hit the main corrugated road.

so im rekonning that somehow the water caused this pressure relief o-ring circled above to pull in suddenly, leaving the o-ring dislodged slightly, and the corrugations would have been the final nail in the coffin.

thats just my guess anyways. not really 100% on how that valve works, but my guess is for when it cools rapidly, whereas the other small black canister above it in the assembly is to allow vapour to escape to the canister.

[stockman]

Please make $1 cheque payable to cuzztec!!!!!

[Moag]

Shep does some pretty dodgy stuff that just works but tends to involve some fire.

We all learn from Shep.

[Scales]

haha he can take it out of my singed leg and hand hairs. ow.

nah srsly, thanks for all your help guys. now i need to get this starter motor out and re-lubed it sounds like a cement mixer at the moment.
i heard its a pretty hard job?

[zukenutter]

Scales wrote:

haha he can take it out of my singed leg and hand hairs. ow.

nah srsly, thanks for all your help guys. now i need to get this starter motor out and re-lubed it sounds like a cement mixer at the moment.
i heard its a pretty hard job?

More that it's difficult to get to.

Congratulations on finding the problem, it's been an epic. Cool to know the cause, I'll have to burn that to memory.

[jimny_timmy]

Have fun cleaning the bull dust mate haha... Glad to see its fixed!!!

As for the starter motor... I think you have to take the intake manifold off to get to it? Stekky might now a quicker way

[Scales]

great i just put manifold back together too.. lol

well i got it all back in one piece, took her for a spin, works like a champ.

theres a few knocks that werent there before but thats what you get from doing the cape trip i guess. Ill go through and tighten shit up under the car when i give it a pressure wash tomorrow.

now i can finally look at posting the trip pics on here too now!

[jimny_timmy]

Scales wrote:

great i just put manifold back together too.. lol

well i got it all back in one piece, took her for a spin, works like a champ.

theres a few knocks that werent there before but thats what you get from doing the cape trip i guess. Ill go through and tighten shit up under the car when i give it a pressure wash tomorrow.

now i can finally look at posting the trip pics on here too now!

Trip report? I'm super keen on hearing how th Jim went! I'm doing the trip this coming June

[atari4x4]

pack a spare fuel pump O'ring.

[Reubs]

Scales wrote:

great i just put manifold back together too.. lol
now i can finally look at posting the trip pics on here too now!

Great work Scales. Good to hear the problem is fixed!

Looking forward to seeing how well the Jimny went before the fuel issues with a few pics!

[zukenutter]

In retrospect I'll bet you're glad you didn't sit on the side of the road until you fixed it

[Scales]

yeah im kinda pissed that we almost got the tank out in the 1st place and even saw the little valve causing the probs. just had no way of knowing on side of road.
one thing you should all know. if you wanna take the tank out. have some plastic handy to shove in the fuel hose connectors to release the jaws. otherwise you wont get em out.

other than the dramas, the car made it all the way there and back, tackling all the hard shit. it only broke down a short distance from the bitumen, so yeah. coulda been a LOT worse. we saw broken down cruisers and a flipped camper trailer. these guys had to pay a fortune to get cars back to cairns.

[stocker]

You should change the title of the thread to " How to go the long way about finding a stupid dislodged o-ring in a Jimny " so people can find it for next time this occurs... and the blue moon rises again...


Congrats on the fix btw glad to hear you didn't have to resort to selling it