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Discussion Starter · #1 ·
Evening all!

So...about 6 months ago I picked up a late 2001 GUII with the ZD30 engine. I'd done a little trawling so was aware of the potential pitfalls, but decided to take a chance.

Jump to last Saturday and I was to be found on the side of the Pacific Motorway with an engine that was cranking but refusing to start, beginning to get that sick feeling in the pit of my stomach that the ZD30 effect was kicking in. It's been towed back up here to Brisbane and plugged in to reveal P3 and P6 error codes - the injection pump if the two service centres I've called are to be believed. Both are quoting about 4.5K to fix it (3K recon part, 1.5K labour).

This brings me to my questions... Firstly, has anyone on here had a success in replacing one of these themselves (from the manual it looks an interesting job), and second, if I'm going to get someone in the Brisbane area to do it for me, does anyone have any recommendations of who to trust on a job like this?

Thanks in advance for any help/advice on this (other than "you should have bought a 4.2 instead"!)

Lee
 

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Discussion Starter · #2 ·
Pump fixed...new problem??

A quick update...

Ended up getting the truck fixed by The Diesel Specialists up in Virginia. They found a cracked cooling fan, several missing fan shroud screws and a couple of missing clamps off the injectors, and replaced the fuel filter at my request. All up it cost about $4800 :(

Seems to be generally ok, though I have noticed:

-A little bit of belt noise on start up from cool/damp conditions, and a slight squeak as the engine slows to a stop after I turn the ignition off following being run for a while. I suspect they've put a belt on a little slack - any thoughts?

-It's started dropping into limp mode under a very specific set of conditions. At around 2900-3000 revs, applying any more than about half throttle causes it to kill the power fairly swiftly, remedied immediately if you lift and then re-apply throttle. Happens in 4th, and more readily going up hill. I first noticed it on changing down from 5-4th with a 2t boat on the back trying to maintain approx 100kph on a motorway incline. I'm pretty sure this is something I would have noticed before, but not sure how a new filter and injection pump could have caused this. From what I've read on here (spent all friday afternoon reading the many posts on this topic) this is an overboost issue, but needs a boost gauge to confirm it. Thought's anyone (for the record, I don't have NADS fitted...but am seriously considering it!)?

Thanks anyone for thoughts on these matters - particularly the limp mode diagnosis,

Lee
 

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Ive replaced a few of these zd pumps and as long as you follow the manual you shouldn't have a problem, just a fiddly job with normal sized hands:)
 

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Discussion Starter · #5 · (Edited)
Sadly I've got no code reader so not sure if it's throwing the 0905 (??) code that some people have suggested they get when this happens.
 

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Have a search on here (ZD30 ref doc), will show you which two pins to bridge on diagnostic plug to retrieve codes via flashing dash light. Really easy to do, I keep 20cm of wire in the car for occasions like this.
Good luck. (I've have been sorting out limp issue due to bubbles in fuel line)
 

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Discussion Starter · #7 ·
New problems...and codes read.

Evening all.

A quick update, and request for more advice...

I hadn't gotten round to reading the codes up to now, but new developments have spurred me into action. Following a beach trip and a slight dunk (to about door-sills height) in some deeper than expected brackish water I have a new problem: the car at times starts perfectly, at others refuses to turn over completely, then turns slowly, then more quickly, then starts. It's very odd, and sounds initially like a flat battery...however as you turn the key a couple of times it seems to almost "wind up" and start. I've tested the battery voltages (14.2/12.9V) and all seems fine there, so thinking it's an electrical gremlin somewhere, or I've knackerd the starter motor.

Following the third occurance of this behaviour, I've also now got an engine management light showing up permanently.

I've read the codes this evening, and have pulled down the following:
-0905
-0703
-1401
These just seem to repeat in that order ad-infinitum...I got bored after the 40th cycle and stopped reading having decided that it must just repeat the same ones rather than showing the frequency of each occuring.

Now, given that the IP was replaced recently (and I assume old codes cleared by the specialist) the 0703 concerns me and I'll be speaking to them about it tomorrow. I don't want to clear the codes as yet for this reason. The 0905 I'm pretty sure I can pin down (see previous post) to particular events - I have plans for NADS treatments to see if I can stop this. The 1401 (security system) has me rather baffled however.

So...my questions I guess are:

-Do my judgements so far seem reasonable?
-Does anyone have similar experience of my starting troubles?
-Has anyone any extra info on the 1401 code please?

Many thanks for any advice on this topic,

Lee
 

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Your sudden loss of power sounds like overboosting, fit the nads and all will be one clear. The overboosting is a funny one, I service every 5k and do the air filter as soon as the oil becomes too much.
It will overboost with a new filter in eve though I hadn't adjusted my boost.
How many k has the motor done?
 

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check thoroughly all grounds, fuses and electrical contacts, starting from battery trough all conections up to the ECM.
in my opinion you have changed the IP for nothing.
DTC's like 0703, 0707 I see often, by now all of them caused only by bad electrical contacts, nothing serious.
 

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Discussion Starter · #10 ·
Oh-so-simple solution...

Evening all. Realised I never came back online to report the final fix... Apologies for that.

The problem turned out to be a cell failure on the battery. It was holding surface charge, hence showing fine on the voltmeter, but when cranked with the metre in place showed a significant drop in voltage. This was enough to mess with the signals going to the ECU, hence to kick off the 0703 and the 1401. New battery...no more issues for the last 9 months.

Overboost... This hasn't occured again since my last post. Seems as though a slight change in driving style, avoiding certain conditions, has stopped it. Will be interesting to see if the new air filter that's due soon leads to the problem resurfacing as suggested by one member.

Anyhow...thanks for the help and suggestions,

Lee
 
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