1996 KZJ78 starting issue

peter_Kzj78
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1996 KZJ78 starting issue

Postby peter_Kzj78 » Tue Mar 02, 2021 9:38 pm

hi all,
can´t believe the bad luck I am having with the truck.
just had everything welded up and repaired for inspection.
saturday morning I got in the truck and it started spot on after sitting weeks in the cold driveway, temps here in central Europe around zero at the moment.
just moved it out of the driveway to make room for work on the Delica and when I wanted to move it back in same day but 6 hrs later it would not start at all.
now the fact part:
glow plug light - not on at all, no current to glow plugs
engine check light - not on at all when turning ignition on, same as glow plug light
injection pump gets around 11V which I believe is ok from previous reads on previous problems?
but: injection pump does not get triggered.
the engine turns and turns but there is absolutely no fuel to injectors, no smoke at all nothing, just dry dead

I have now located the glow plug relay and starter relay, glow plug relay not powered.

where do I find the main relay that goes by no. 85915-60030? are there two of it? parts reference picture is showing two units but not exact location.

will have to take out second battery later to see if it is there in the left fender? like the other two relais are?

any guesses?

thanks
Peter

peter_Kzj78
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Posts: 93
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Re: 1996 KZJ78 starting issue

Postby peter_Kzj78 » Wed Mar 03, 2021 5:02 am

hi all,

I have continued the search for the impossible.

what I did today:

tested both main relays, oem no 85915-60030

does anyone know why there are two main relais?
one is on a grey plug the other on a black plug.
switched the relais and both are klicking with ignition on if connected to the grey plug. on the black plug neither of them. so, what is this circuit, where does it come from?

as written before, checked all fuses. are there any fuses hidden in engine bay? don´t think so, did not see any on any diagrams and part lists.

i have then also taken out the ECU. inspected the boards, look absolutely clean, no leaking parts whatsoever. of course no electronic check but there is power going there as the small chip box connected is powered from there and LED is on.

I am now stuck here
does anyone have a wiring diagram? any hint?

tia

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bigstu
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Re: 1996 KZJ78 starting issue

Postby bigstu » Fri Mar 05, 2021 8:19 am

I have a hilux 97-05 diagram not sure if any help but might be similar?

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bigstu
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Location: Invercargill

Re: 1996 KZJ78 starting issue

Postby bigstu » Fri Mar 05, 2021 8:31 am

From what i can see the ign fuse covers both pump and glow plug timer
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peter_Kzj78
Bush Crasher
Posts: 93
Joined: Mon Jun 30, 2014 4:11 am

Re: 1996 KZJ78 starting issue

Postby peter_Kzj78 » Fri Mar 05, 2021 6:31 pm

thanks Stu! diagram says 5L engine but logic might be very similar, I will compare with the japanese version i found on ih8mud.

how or where do I best share the japanese version if anyone else is interested?

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