No start Vehicle No Diesel Fuel to injectors


Toyota Surf LN130, 2.4L 2L-TE Diesel engine


The Toyota Surf came into the workshop with a no start condition.


Cranking the vehicle was no issue and the first check for any diesel that wont start is to crack a diesel fuel line to check for fuel pressure. With no fuel at the injectors it time to check that fuel was getting to the fuel filter, removing the line from the diesel fuel filter and priming the fuel line with the hand pump is a great start, that tested fine and the diesel fuel supply was OK to the diesel fuel pump.

We decided to check to make sure the fuel pump was spinning by checking that the timing belt was in tact we removed the timing cover top to check that the pump was spinning with that in check, we decided that the pump must be faulty.
Not being a diesel specialist and the surf being an electronically controlled diesel we decided to remove the pump and send it away to be tested and overhauled.

Once we got the pump back and fitted it back to the vehicle, the engine would crack but still no pressure to the injectors.Components_on_injector_pump
Now we had to learn about how diesel works, especially how electronic diesels work.

we grabbed a wiring diagram found on the Internet and decided to check all the circuits that would be essential to firing up the fuel pump. Usually all diesel pumps have a shut of valve this vehicle being electronic, it did not have a shut off valve that we could see on the diagram, i have put instructions and testing methods overlaid on the wiring diagram.
On the surf they call it a spill control valve, not having too much experience with diesels we called a few mechanics in the area to ask about testing the valve and they said the valve is controlled by the computer and is a pulse width modulated opening valve, however the computer wont open the valve unless the crank sensors are working during cranking.

Full Diagnostics

Understanding the wiring diagram and found that there is a TDC sensor (crank Position sensor) and revolution signal (NE+) both of which where working fine.
We tested the electronic spill valve circuit and foudn that when ignition was first turned on the ECU would provide a ground circuit for a split second. (SPV – terminal)
So we decided to manually over ride the ECU and Provide a ground circuit for the Electronic Spill valve, To our sucess the engine cranked and ran however the engine would Rev to high as the computer was not controlling the amount of fuel to the injector pump.

Testing the circuits concluded that the ECU was faulty, finding a second hand unit was the next challenge, being that the vehilces where only private imports

Wiring diagrams


NE+ Waveform







Fault Code Table

OBD1 Codes
1 Normal Condition.
2 Air Flow Meter signal.
3 Ignition signal.
4 Engine Coolant Temperature Sensor signal.
5 Oxygen Sensor.
6 RPM signal (Crank Angle Pulse).
7 Throttle Position Sensor signal.
8 Intake Air Temperature Sensor signal.
9 Vehicle Speed Sensor signal.
10 Starter signal.
11 Switch signal.
12 Knock Control Sensor signal.
12 RPM signal.
13 Knock Control CPU (ECM).
13 RPM signal.
14 Turbocharger Pressure.
14 Ignition signal.
21 Oxygen Sensor.
22 Engine Coolant Temperature Sensor signal.
23 Intake Air Temperature Sensor signal.
24 Intake Air Temperature Sensor signal.
25 Air-Fuel Ratio Lean.
26 Air-Fuel Ratio Rich.
27 Sub Oxygen Sensor signal.
28 No. 2 Oxygen Sensor signal.
31 Air Flow Meter signal (Vacuum Sensor signal).
32 Air Flow Meter signal.
34 Turbocharger Pressure signal.
35 Turbocharger Pressure Sensor signal.
35 HAC Sensor signal.
41 Throttle Position Sensor signal.
42 Vehicle Speed Sensor signal.
43 Starter signal.
51 Switch signal.
52 Knock Sensor signal.
53 Knock Sensor signal.
54 Inter-cooler ECM signal.
71 EGR System.
72 Fuel Cut Solenoid signal.
78 Fuel Pump Control signal.
81 TCM Communication.
83 TCM Communication.
84 TCM Communication.
85 TCM Communication.