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1HD-FTE Injection Pump Suspected. Please Help!!

Dwi Atmaji

New Member
Joined
Mar 28, 2020
Messages
9
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indonesia
Hi all,
My 2003 HDJ101 Sahara (AU domestic market version) is acting up. It would start and act normally when cold, no starting issue at all. However, the engine will be unable to start after a long drive and things gets hot. The symptoms are really weird, after things get really hot and I kill the engine and immediately re start it the engine would re start in a single crank with no problem at all, but if I leave the engine off for a few minutes it will refuse to start until after 45 mins or so (when things start to cool down), the engine would turn over normally but unable to come alive.
I have had this problem for a while, it was much worse before with the engine spontaneously stall when hot and refuse to restart until after 1.5-2hrs. I initially was able to fix it by cutting the plugs on the spill valve and made direct soldered connection bypassing the spring loaded plugs on the spill valve directly to the EDU wire. Turned out after a month the problem re appears. I have replaced all fuel feed and return hoses, fuel filter mount/fuel primer pump, purged the fueling system with Liqui Moly diesel purge yet the strange problem persist. I have consulted with 2 specialists and both pointed their fingers on my Injection Pump......I initially refused to believe them because it’s too easy to replace the most expensive part and the engine is revving fantastic and there were plenty of power, but now I begin to doubt myself. Lately I could feel the engine losing a bit of power and not as lively when hot and becomes lively again when cool, a sign of worn Injection Pump? Can anybody advise me to which direction I should look at before biting the bullet and buy a new and very expensive Injection Pump?

thanks in advance!!
 
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Additional informations that might be useful in diagnosing my problem:
The engine feel really zippy and lively when first started in the morning (after warmup off course) and continue to feel lively as long as its not fully warmed up and begin to feel sluggish after being driven for a distance and things are at operating temp (for a diesel engine). The diesel specialist said that worn Injection Pump could act that way. I do have a faint white smoke coming out from my tailpipe, not thick smoke and definitely not blowing thick smoke under heavy acceleration. Could it be that I have worn piston ring so there is no compression when engine is at full operating temp therefore the inability to start the engine when hot? Diesel engine = no compression no start?
 
I think I might have gone cray crayzey LOL!! The more I look through my own post again the more I suspect I might have compression problem when hot, no compression = no cylinder firing? Like I said before I do have white smoke coming out my tailpipe and oil filler hole, definitely not a billow of smoke but steady stream of faint white smoke indicating that I do have ring leak? It might also worth mentioning that after prolonged steady RPM drive and I let go of the gas pedal entirely, sometime there could be a thick billow of white smoke spewing out of my tailpipe for a short burst, it happen randomly, most often after a long sustained steady high rpm run. Perhaps despite the not so thick white smoke the compression leak is actually bad enough to cause failure to start when fully hot?
 
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Hi Dwi,

Whats the Mileage/Kilometes on your 100?
Hi Jibberjabber, it’s 135.000kms. For sure the truck has been through a lot of crappy fuel in its life. Good quality diesel fuel does not exist in Indonesia until after 2005, and even then not many willing to pony up for the good diesel fuel until recently when common rails start flooding the street
 
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Hi Jibberjabber, it’s 135.000kms. For sure the truck has been through a lot of crappy fuel in its life. Good quality diesel fuel does not exist in Indonesia until after 2005, and even then not many willing to pony up for the good diesel fuel until recently.
Not very high mileage at all only 84,000, just a thought as I'm no expert, have you tried removing the fuel filter filling it with Diesel injector/fuel system cleaner, refiting then start engine, I saw an MOT guy do this when the emissions were to high, it worked, just a thought.

Has your 100 got more than one fuel filter?
 
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Not very high mileage at all only 84,000, just a though as I'm no expert, have you tried removing the fuel filter filling it with Diesel injector/fuel system cleaner, refiting then start engine, I saw an MOT guy do this when the emissions were to high, it worked, just a thought.

Has your 100 got more than one fuel filter?
I did that too, still the same problem. It’s got one fuel filter by the engine bay. There is no aftermarket addition as far as I know.
 
Upon my own reading seems like my problem is indeed the Injection pump..... Some googling revealed that diesel engine with worn piston rings tend to start easier when warm compared to when cold, mine is acting the total opposite. It is also been said that my symptom is typical of worn barrel and plunger on injection pump, worn barrel and plunger can still carry cool fuel and cannot carry hot fuel....??
 
Hi Dwi,

Start by eliminating potential problem areas - a compression test would tell you if it is the rings - but also look at simple things like is there a short flex pipe in the fuel line where the feed pipe joins from the chassis mounted pipe to the engine. These pipes swell inwards as they decay and restrict the fuel flow to the pump and as they get warm/hot they swell even more. I had a similar problem - power reduction when it got warm/ reducing power on a long run and refusal to start until it cooled. After renewing that pipe the problem has never re-occurred.

Regards,

Rodger
 
Hi Dwi,

Start by eliminating potential problem areas - a compression test would tell you if it is the rings - but also look at simple things like is there a short flex pipe in the fuel line where the feed pipe joins from the chassis mounted pipe to the engine. These pipes swell inwards as they decay and restrict the fuel flow to the pump and as they get warm/hot they swell even more. I had a similar problem - power reduction when it got warm/ reducing power on a long run and refusal to start until it cooled. After renewing that pipe the problem has never re-occurred.

Regards,

Rodger
Hi Rodger, thanks for the insight. I have replaced all 4 Rubber hoses from the fuel pipe to filter, filter to injection pump, fuel return line to damper and damper to pipe going to tank. Is the pipe you mentioned something else? Do you have a picture or diagram of the pipe you mentioned? Thanks
 
Hi Dwi,
By replacing the pipes you have probably renewed it but it is the one that absorbs the engine vibrations so from the chassis to the engine mounted pipework. Should be fuel line (re-enforced) not ribber, although I appreciate that 'rubber' could be just descriptive.
Ooh I just re-read the intro and it;s a 100 series - and there I was , going from your avatar, that you had a 40 series. Therefore it is probably completely different!
Regards,
Rodger
 
Hi all,
My 2003 HDJ101 Sahara (AU domestic market version) is acting up. It would start and act normally when cold, no starting issue at all. However, the engine will be unable to start after a long drive and things gets hot. The symptoms are really weird, after things get really hot and I kill the engine and immediately re start it the engine would re start in a single crank with no problem at all, but if I leave the engine off for a few minutes it will refuse to start until after 45 mins or so (when things start to cool down), the engine would turn over normally but unable to come alive.
I have had this problem for a while, it was much worse before with the engine spontaneously stall when hot and refuse to restart until after 1.5-2hrs. I initially was able to fix it by cutting the plugs on the spill valve and made direct soldered connection bypassing the spring loaded plugs on the spill valve directly to the EDU wire. Turned out after a month the problem re appears. I have replaced all fuel feed and return hoses, fuel filter mount/fuel primer pump, purged the fueling system with Liqui Moly diesel purge yet the strange problem persist. I have consulted with 2 specialists and both pointed their fingers on my Injection Pump......I initially refused to believe them because it’s too easy to replace the most expensive part and the engine is revving fantastic and there were plenty of power, but now I begin to doubt myself. Lately I could feel the engine losing a bit of power and not as lively when hot and becomes lively again when cool, a sign of worn Injection Pump? Can anybody advise me to which direction I should look at before biting the bullet and buy a new and very expensive Injection Pump?

thanks in advance!!
Hi Dwi,

Any news/updates yet?
 
It's worth getting a compression test done as it would rule out compression issues. Try and do it hot if possible. I know on the 4 cylinders you have good access to about 3 of the glow plugs without removing the manifold, I don't know if this is the same for the 6 cylinder engines.

On the other hand, I'd check the resistance specs on the pumps valves, especially the spill control valve. If you can do hot/cold readings that would be great.
 
No glow plugs on the FTE, you have to use the injector holes and make an adapter.
 
Hi dwi
I just joined the forum.. And i have exactly the same issue as u described... I hope you figured out what the problem and i also hope that it is not the pump
Please tell me how this story ended
 
Hi Dwi et all. While we are this subject, does anyone know if the injection pump from HDJ101 can be fitted into HDJ79. I know the HDJ79 version are not intercooled apart from being the same 1HD-FTE motor. If so, what are the difference?
 
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