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My hilux 1kd-ftv wont start 3.0 d4d return fuel line full pressure

I change fuel pump ,fuel rail,turbo solenoid,fuel filter,drain fuel and fill new diesel

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If it is a common rail diesel then the pressure in the return line would burst it as the line is not capable of 25.000 psi
so the return line will have low pressure if it is blocked some where

have the injectors tested as there may be a tip seat problem that prevents it from starting and the compression pressure is making the pressure in the return line past the needle

Posted on Sep 16, 2015


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Have to remove the tank to get all the water out, then refuel . Fit a new fuel filter .disconnect the return line at the fuel rail, work the fuel pump to expel any water from the fuel lines and rail ,connect the return line and start.

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Hi, I own a 3.0 d4d toyota fortuner (same engine as 3.0 d4d hilux) and as of yesterday it started belching white smoke. it starts and idles perfectly fine, the exhaust just smells off. not like unburnt...

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In what condition was the filter you removed? How bad? Temperature issues? Missing coolant maybe? If yes, you might as well have an internal leak. Some gasket maybe. Check all you vital fluids levels. If anything missing, take the time to empty the engine oil on a can, and check the colour. If it will look like chocolate brown, then you do have a leak from the inside.

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Jambo Jambo.This problem, unfortunately is going to be in the fuel injector pump itself. If the veins are wearing it will begin to fail at high RPMs when the fuel demand is high. You are on the right track though. It is fuel. Replace the injector pump and time accordingly. Feel free to contact me if you need anything else.

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Started ran for awhile then died an wont start

Start with the simple and replace your fuel filter, a dirty filter can cause your engine from starting. At worst, your fuel pump has failed and will need to be replaced. Before replacing the fuel pump, inspect all the fuses and wire leads from the fuel pump harness. Note: that the ground wire is separately grounded at the frame, so inspect that for any damage due to corrosion.

You need 3 things.
Good hot blue spark to all plugs.
Good gasoline and proper fuel pressure. 63-64 lbs.
If you have all 3 then move on to injector pulse to all injectors. I think each injector is on a seperate driver on that one. Check for pulse to all of them.

You may be weak on fuel pressure, even a couple of lbs low on a cold start will cause a no start. Double check cold start cranking fuel pressure. If under 63-62 lbs you have problems. One test is to give it a squirt of carb cleaner not starting fluid. If it starts then you have a fuel pressure problem.
Run the full fuel pressure test, here is the guide lines on testing.
Hard to start cold.
Check cold start fuel pressure.
Check engine running fuel pressure.
Check engine running on the road fuel pressure.
Then shut it off and watch for fast leak down.
Pinch off at rubber part or block off return line and check full pressure. Later V6 and V8 gm engines should have 60-66 fuel pressure.
* Cold start should be 64-65 lbs of pressure. If you do not have full fuel pressure on a cold start the injectors will not squirt fuel.
* Engine running should be 60-66 lbs pressure depending on engine load.
* Full pressure with return pinched off should be 75-85 or more. and if it has a fast leak down after shut off you have a leak.

The 75-85 is only a check on the capable full pressure of fuel pump. If you can not find the rubber return line check full pressure by plugging return line or just or the true full pressure can be taken direct at the end fuel filter.

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My 1990 chrysler imperial will idle fine but it dies when you give it gas.I changed the fuel pump and both computers and i'm still having the problem.

Sounds as though it may be your fuel pressure regulator. Easy fix and you can troubleshoot it easily also. Check the fuel pressure first. This is your part....

Fig. 13: Compression gauge and a combination vacuum/fuel pressure test gauge

TESTING Except Premier and Monaco NOTE: To perform this test, you will need a pressure gauge capable of reading pressures above 55 psi (379 kPa). The gauge must have a connection that will fit the fuel rail service valve. The gauge must be the equivalent of Chrysler pressure gauge No. C-4799 and the connector fitting compatible with pressure test adapter 6539. You may also need a T and the fittings necessary to connect the gauge into the fuel supply line at the tank, as well as a 2 gallon container suitable for collecting fuel.
  1. Release the fuel system pressure as described in Section 1.
  2. Disconnect and plug the vacuum line going to the fuel pressure regulator.
  3. Remove fuel hose quick connector from the chassis line.
  4. Install the adapter between the fuel supply hose and chassis fuel line assembly for the 3.0L engines or into the service port of the fuel rail for 3.3L and 3.8L engines.
  5. Hold the gauge and have someone start the engine. Run the engine at idle speed in Neutral (manual transaxles) or Park (automatic transaxles). CAUTION
    Exercise extreme caution while under the hood with the engine running. Keep clear of all moving belts, fans, exhaust manifolds, etc.
  6. Read the pressure. It should be 48 psi (330 kPa). If it is outside the range, take note of it.
  7. Stop the engine.
  8. Once again depressurize the system, disconnect the gauge and replace the protective cover.
  9. If the pressure was correct, the test is complete. If the pressure is below the range, proceed with the next step; if it is too high, skip to Step 13. WARNING
    In the next step, note that fuel may drain from the lines as you disconnect them. Make sure all surrounding exhaust system parts are cool and that all sources of ignition are removed from the area. Collect fuel and dispose of it safely.
  10. Connect the gauge into the fuel supply line running between the tank and the filter which is located at the rear of the vehicle. WARNING
    Make sure all connections are secure.
  11. Have an assistant start the engine, then read the pressure gauge. If the pressure has risen more than 5 psi (35 kPa), replace the filter. If the pressure is now within range, allow the engine to cool and remove all sources of ignition; depressurize the system; disconnect the gauge from the lines; replace the fuel filter; and restore all connections.
  12. If the pressure is still too low, gently and gradually pinch the fuel return line closed as you watch the gauge. If the pressure increases, the fuel pressure regulator is at fault. If there is no change, the problem is either clogging of the filter sock mounted on the pump or a defective pump itself.
  13. If the pressure is too high, follow this procedure:
    1. Shut off the engine and allow it to cool.
    2. Depressurize the fuel system, then disconnect the fuel return hose at the chassis, near the fuel tank.
    3. Connect a 3 ft. (91cm) length of hose to the open end of the line running along the chassis. Position the open end of the line into a container suitable for collecting fuel.
    4. Have a helper start the engine, then check the pressure again. If it is now correct, check the in-tank fuel return hose for kinking.
    5. If the in-tank fuel return hose is okay, and the system still exhibits excessive pressure with the tank half full or more, the fuel pump reservoir check valve or aspirator jet may be obstructed and the assembly must be replaced.
  14. If the pressure is still too high, perform the following:
    1. Shut the engine OFF, and allow it to cool.
    2. Depressurize the system once again and reconnect the fuel lines at the rear.
    3. Disconnect the fuel return hose at the pressure regulator. Collect all fuel that drains.
    4. Run the open connection into a large metal container.
    5. Reconnect the fuel gauge to the fuel rail.
    6. Start the engine and repeat the test. If the fuel pressure is now correct, clean a clogged return line or replace pinched or kinked sections of the return line. If no such problems exist, replace the fuel pressure regulator.
Premier and Monaco CAUTION
Wear eye protection when servicing the fuel system. Do not smoke or allow open flame near fuel system components during fuel system service.
  1. Remove the fuel tank filler cap to relieve the fuel tank pressure. NOTE: System fuel pressure will be released when disconnecting the fuel supply tube. Have shop towels handy to absorb spilled fuel.
  2. Use the quick disconnect tool 6182, or equivalent, to remove the black fuel supply tube from the fuel rail. Slide the tool over the nipple and up into the connector until the handle fits the connector. Pull the fuel supply tube off the fuel rail.
  3. Install the fuel tube pressure adapter tool 6175, or equivalent.
  4. Push the female end with the quick-connect fitting over the fuel rail until a click is heard. Pull the connector back to ensure that it is locked in place.
  5. Push the male end with the nipple into the black fuel supply tube until a click is heard. Pull the nipple back to ensure that it is locked in place.
  6. Attach a 0–60 psi (0–415 kPa) gauge from the fuel pressure test kit 5069, or equivalent, to the port on the fuel tube pressure adapter tool.
  7. Start the engine and check the fuel pressure. It should be 28–30 psi (193–207 kPa) for early models and 43 psi (300 kPa) for late models. The fuel pressure regulator on these vehicles is non-adjustable.
  8. If the fuel pressure is low, check for fuel flow through the return tube.
    1. If fuel is returning to the fuel tank through the fuel return tube, replace the fuel pressure regulator with a new one.
    2. If the fuel is not returning to the fuel tank or just trickling out, inspect for a faulty fuel pump, possible clogged fuel filter or other restriction between the fuel pressure regulator and the fuel pump.
  9. If the fuel pressure is high, check the pressure regulator vacuum hose for leaks, and for a kink or restriction in the fuel return hose. If the pressure regulator vacuum hose is not leaking, the return tube is not kinked and does not have a restriction, the fuel pressure regulator should be replaced with a new one.
  10. Remove the pressure gauge.
  11. Disconnect the fuel tube pressure adapter tool with the quick disconnect tool.
  12. Prior to installing the fuel tubes to the regulator and fuel rail the tube ends must be lightly lubricated with clean SAE 30 weight engine oil. Refer to the procedures describing the removal and installation of the fuel tubes.
  13. Install the black fuel supply tube to the fuel rail and the gray fuel return tube to the pressure regulator.
  14. Install the fuel tank filler cap.
  15. Start the vehicle and check for fuel leaks. NOTE: When starting the engine, allow extra time for the system to pressurize itself.

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