XJ 2025H just quit

[jsf729]

Was bush hogging and machine was running fine. All of a sudden started shaking violently with low power. I immediately disengaged PTO. Little change. Fortunately I was close to where I park it (about 30 feet) and was able to limp it there. It turned 500 hours when I was cutting and planned on 500 hour service when I was done. Some of the service includes fuel filter change and checking injector pump pressure. i was hoping that it was just the filter causing the problem. Sure enough, there was a lot of sediment in the bowl. Cleaned it out, changed the filter and bled the system. Now just cranks and won’t start. I’m guessing some sort of fuel delivery problem. My question is order of operation. Can clogged injectors run fine and then just quit? My guess is no, that it would be gradual. So that would be the injector pump. Or am I missing something? Battery is 12.69 vdc. Seat safety switch is jumped out. Also it’s a well known fact that these 3 cylinder Mitsubishis shake under 1200 rpm. So the extremely low rpm would explain the shaking I’m guessing. Thanks in advance

 

[alexpops]

Fuel solenoid operating properly? Do you have an electric fuel pump on that model? is that working? Intake screen plugged in tank? Vent? Will it start if you loosen the fuel cap? If all that checks out, maybe try bleeding the lines again?

 

[GS650GL]

How did you bleed the fuel system? Just bleeding the filter may not be enough. Try loosening all the fuel injection lines at the injectors and then crank it for awhile and see if you can get fuel to the injectors. There may still be air in the lines between the pump and injectors. If the injection pump is still not delivering fuel to the injectors, there may be an electrical problem. First check all the fuses which are hard to get at behind the steering column panel on that model. There is also a small electronic module under the dash that takes all the inputs from the safety switches and determines if it will let the engine start and stay running by controlling the power to the fuel solenoid. On some XJ's, there is also a twin relay under the dash that can cause a crank but no start condition if it fails.
These engines need to idle at least 1300 RPM or they will shake themselves to pieces like you said. There were lots of broken mufflers and brackets and even dipsticks that snapped off on early XJ's until the idle speed was turned up to 1300.
Just curious, how were you planning to check injection pump pressure as part of the 500 hr. service? There's not a way to do it that I'm aware of.

 

[jsf729]

Fuel solenoid operating properly? Do you have an electric fuel pump on that model? is that working? Intake screen plugged in tank? Vent? Will it start if you loosen the fuel cap? If all that checks out, maybe try bleeding the lines again?

Thanks for your reply. No electric fuel pump, fuel delivery from tank is strong. I tried bleeding again but no change.

 

[jsf729]

How did you bleed the fuel system? Just bleeding the filter may not be enough. Try loosening all the fuel injection lines at the injectors and then crank it for awhile and see if you can get fuel to the injectors. There may still be air in the lines between the pump and injectors. If the injection pump is still not delivering fuel to the injectors, there may be an electrical problem. First check all the fuses which are hard to get at behind the steering column panel on that model. There is also a small electronic module under the dash that takes all the inputs from the safety switches and determines if it will let the engine start and stay running by controlling the power to the fuel solenoid. On some XJ's, there is also a twin relay under the dash that can cause a crank but no start condition if it fails.
These engines need to idle at least 1300 RPM or they will shake themselves to pieces like you said. There were lots of broken mufflers and brackets and even dipsticks that snapped off on early XJ's until the idle speed was turned up to 1300.
Just curious, how were you planning to check injection pump pressure as part of the 500 hr. service? There's not a way to do it that I'm aware of.

Thank-you for this valuable information. You are obviously very familiar with this model. Actually I did loosen the pipes feeding the injectors and cranked the engine. I did see some weeping, figured that was it and tightened them back and tried starting but no luck. Tried it again but this time no fuel. Could that have been residual fuel left from when it last ran? I am hoping that it is electrical as I’m guessing a new pump is expensive. I’ve been at the fuse panel before and it is a pain. I have the schematic and will investigate further the other possibilities that you mentioned. No, I have no way of testing pump pressure but mentioned it because it may have been pertinent to my problem. I am on my second muffler, the first one replaced under warranty. Supposedly the replacement is more robust but I don’t see any difference. I shut it down at 1200 rpm always. It’s actually a smooth running engine and haven’t had any problems with it till now.

 

[jsf729]

Thanks for your reply. No electric fuel pump, fuel delivery from tank is strong. I tried bleeding again but no change.

Talked with the dealer today. He said to confirm fuel solenoid operation since he has seen them fail. Although I could hear it I pulled it anyway and it is good. He believes that it is either a partial clogged fuel tank and/ or air in the system and has not seen pump failures on this model. Suggested sticking a rag in the fuel tank opening and pressurizing the tank. I can’t get my compressor close enough. I guess next step is bypassing the fuel tank and feed directly from fuel can. Lots of rain the next couple of days so won’t get to it till weekend. Thanks again for all the feedback

 

[Ericredslslingshot]

My solenoid went with less than 100hrs. Expensive to replace. Engine would crank but not start.

 

[bgr]

1. If you think you have sediment in the tank, disconnect the tank line from the feeder side of whatever pump or filter it goes to before you blow out tank. Don't want to blow dirt into the rest of the fuel system. AND don't use full air pressure on the tank, just a little. Easy to damage with high air pressure.

2. It is most likely you still have a problem with an airlock somewhere. Keep trying to bleed. You should get a reasonable but not great flow at the injectors. To check run the injector line nut up hand tight and back off just a hair. If the pump is primed, the pressure should spray fuel out. Injector pumps run for thousands of hours. Failure at 500 is unusual. Did you get fuel out of the new fuel filter?

 

[jsf729]

My solenoid went with less than 100hrs. Expensive to replace. Engine would crank but not start.

Yep dealer told me if mine was bad to buy one from Amazon for $100. LS wants over $500. Mine tested good though

 

[jsf729]

1. If you think you have sediment in the tank, disconnect the tank line from the feeder side of whatever pump or filter it goes to before you blow out tank. Don't want to blow dirt into the rest of the fuel system. AND don't use full air pressure on the tank, just a little. Easy to damage with high air pressure.

2. It is most likely you still have a problem with an airlock somewhere. Keep trying to bleed. You should get a reasonable but not great flow at the injectors. To check run the injector line nut up hand tight and back off just a hair. If the pump is primed, the pressure should spray fuel out. Injector pumps run for thousands of hours. Failure at 500 is unusual. Did you get fuel out of the new fuel filter?

To confirm if the tank is clogged, could I temporarily run from a 5 gallon fuel tank? That would eliminate the tank as being clogged I’m guessing. If it is in fact the tank I’d drain it and clean in opposite direction of fuel flow.
Good to hear about injector life. My dealer echoed that as well which is good news as they are pricey. Thanks for the tip on bleeding the injectors. I tried various ways from supper loose to fairly tight. At one point I did get some weeping from #3. Fuel flow in and out of the filter seems strong to me but not sure if feed from tank under pump pressure is sufficient
Back on it first thing this morning. Grass is not cooperating and still continues to grow!
A great holiday weekend to all. Take a moment to honor the fallen.