Recurring Airlock in my 94 Diesel Hilux

[faiyaz]

Hi All,

Been having a challenge with my Hilux with a 2L engine for the past few months. When driving for some reason the vehicle switches off due to diesel starvation/ airlock. I have so far dropped and cleaned the tank and flushed hardlines to engine bay, changed the hand pump, rubber hoses and filter unit. Started filling diesel from a different station too. However all of the above have not gotten rid of the problem. My once very reliable Hilux is becoming a worry to take on the highway as it might stop at any second . Any suggestions/ past experiences on a fix/ cause of the above are welcome.

[niclemaitre]

Are you sure that the solenoid valve on the diesel pump is working correctly?

[faiyaz]

I will have a look, its intermitted failure could be a possible cause. any way to test it ? I would have thought if it was not working properly i would experience hard start however the hilux starts up just fine.

[niclemaitre]

Give it 12V and see if you feel it operating?

[faiyaz]

noted, but it will be tricky to rule out the solenoid as on testing manually it may respond normally, if it was not functioning at all the hilux would not start. i still feel somehow air is getting into the diesel suction system causing an airlock. but im not sure where from.

[niclemaitre]

I had a cracked hard line near the tank that introduced air into the lines. We found the problem by replacing a section of the hose in the engine bay with clear hose temporarily

[faiyaz]

Oh I see, that's a tricky one to pick up. Finally found the cause ( I think) so today once again the Hilux cut off on the road and didn't want to start even after priming the hand pump. After alot of trial and error decided to shake the solenoid cable and it started with no problems. On further investigation I found the solenoid supply wire was loose and probably came out of the the crimp connector. Ended up soldering it to the crimp connector. Hope that sorts it!!!