ZD30 New Inj Pump:code 0707
Hi this is my first post and I hope some genius on the forum can make a suggestion that might resolve my injector pump issues which I have been working on for a couple of months.
I initially had a fault code 0707 (injector pump timing) on my injector pump and checked everything I could think off and bit the bullet and installed a refurbished pump 4 weeks ago. After two weeks of smooth running apart from a squeal a couple of times from the injector pump area but could have been the fan belt or exhaust escaping from the egr gasket, on comes the MIL again with the 0707 code.
When the light isn't on the vehicle runs really well. It has good acceleration and torque through all the gears and idles smoothly. When the engine malfunction light does come on resulting in a mini limp mode of about 95km top. I can get normal acceleration back by depressing the clutch and revving the engine to around 4500rpm or putting it in neutral and revving the engine to 4500rpm however the MIL stays on. When I start the engine again which is never a problem the light isn't on but does come on from anywhere between 2 and 30 minutes. I have taken the following steps to resolve the problem:
1) I have replaced the diesel filter (for the umpteenth time) which resulted in no change. The lift pump was changed recently as it had a ruptured diaphragm.
2) I checked for air bubbles in both the intake and outlet points of the lift pump - no bubbles. Checked through clear plastic tube which is now permanently install.
3) Throttle position sensor was changed about 2 years ago, however I connected the appropriate terminal on the TPS and ran the vehicle in real time and garage tested the voltage values which are as smooth throughout the range with both the engine light on and off. No codes for a faulty TPS are registered.
4)Neutral Position Sensor was replaced to rule out it out last week. No change.
5) Timing chain is good.
6) I have removed the harness between the pump and the wiring loom. Although clean and dry all connections on the harness were cleaned with approved electrical cleaner as was the pump connection poles. A voltage reading was taken at terminal 7 which results in battery voltage - good. Grounding is sound. Good connectivity through all wires.
7) No trouble codes are coming up for the cam shaft sensor and crankcase sensor, however the connections were cleaned with an approved electronic cleaner. No change
8)Manifold charge sensor tests are within recommended values, sensor cleaned and the connector as well.
9) Air temperature sensor tested okay.
10) Turbo charger actuator functions as expected.
11) Swirl valve and actuator function as expected.
12) EGR is producing no trouble codes. The engine has a EGR blank inserted along with the appropriate rerouting of the vacuum lines to the actuator and shut down solenoid from the EGR solenoid. EGR solenoid is still connected only for the ECU monitoring.
13)ECM relay has been cleaned and wiring checked no issues.
14) The wiring loom has been checked from the pump to the ECM and no open or shorts found. All connectors have been inspected and cleaned.
15) The 3 wiring loom earths to the inlet manifold have been cleaned and checked. So has the engine earth.
16) Continuity between the injector pump and ECM terminals 33, 40, 52 and 53 are good.
17) I have noticed that the p77 code seems less frequent with a full tank of fuel and more often with 1/4 of a tank. I checked it with a full tank of fuel and took fuel cap off no change but less likely to come on. I removed 40 litres of fuel and ran the engine with a 1/4 of a tank both with and without the fuel cap on and no change. Light comes on and engine goes into limp mode.
18) I then connected the intake of the fuel filter to a small fuel container (5litres) and the fuel return line from the injector pump to the fuel container. I then drove the vehicle at speed and throughout a range of driving conditions without the MIL coming on, however I pulled up and continued to let it idle for a few minute more and the MIL came on. Total elapse time was about 40mins.
19) Swapped ECU no change in code readings.
20) Driving the car on rough, corrugated Kimberley roads and the highway make no difference. So I have ruled out the a hidden break or loose connection.
21) I have heard that not having a working break light can result in the MIL coming on. I can't see how but the both are working.
Sorry about the long first post but it is the most baffling problem I have had and would prefer not to have to remove the pump again. I have also tried contacting the supplier of the pump but emails and calls are not being returned. So I just hope somebody can assist.
Cheers and thanks for reading the post its very much appreciated.
Mike
Regarding 0707 code - I agree with tweak'e in following thread - it's usually related to blocked fuel filter or air in lines.
I have 2006 D22 dual cab ZD30 STR, 190,000 kms, very little trouble for it's entire life, and about 60,000km offroad.
My experience:
1) Engine light began triggering (MIL) soon after starting and going into limp mode.
2) Initially happening at low revs. 0707 code coming up (no others after cleared fault record).
3) Replaced fuel filter (even though there was no water in it) as well as several slightly leaky and perished hoses into AND out of fuel pump.
4) Result = Engine light no longer triggered at idle, but when revs pushed to 3,000-4,000, then triggered an went into limp mode. Same 0707 error code. Seemed to indicate small air leaks present at higher pressure.
5) Read in another thread (could be by tweak'e - he's knowledgeable and trustworthy) to
check banjo bolts on fuel pump (fuel inlet and outlet).
6) Found they could be tightened by about 90 degree turn to "firm".
7) Problem fixed!
8) Cleared error code, and none has occurred since. Engine light hasn't come back on and that was weeks ago.
9) The banjo bolts weren't loose, but the extra tighten seems to have sealed 1-2 very small air leaks.
Recommend trying this for 0707 code and before attempting more significant repairs like replacing fuel pump.
Good luck, hope this helps someone and if not, don't give up, someone out there will help you find a solution.
