XUD9 starts but dies in 2 seconds

[Robert Gladh]

Hello

I have a Suzuki samurai with the XUD9 TD engine with the lucas pump where a solenoid cuts the fuel flow unless the correct code is entered inside the passenger compartment.

A short summary:
Bought the car and got it transported by a truck since i bought it 5 hours from home, when the car was loaded off, it did not start even if the right code was entred, ie there was no diesel from the injector pipes at all.
After grinding the anti-theft cover that encloses the immobilizer i then removed the solenoid and blew down in the hole with compressed air, then installed the solenoid and the car fired up right away. If it was because of the compressed air or if it was because of all the interuption the solenoid had I we do not know.

Shortly after this I decided to change the cambelt and since then the car does not start more than a few seconds and until it dies again. 

What separates this case from the first one is:
-Diesel comes out of the injection pipes when it is running on the starter
-The car starts and goes for a second or two before it dies

The holes in the camshaft pulley & pump pulley are in line with the holes in the block so I doubt thats the problem, especially when the car starts for a few seconds before it dies.

Have changed:
Glow plugs (they work)
Fuel Filter
Bypassed the fuel filter to see if there is something wrong there
Bleeded filter, inlet to pump and out at the injection pipes.

So all XUD specialist here, what are your theories? I suspect the the solenoid, could it loose the voltage when the engine cranks and release the "plunger" so the car stops? I have tried so many different things so I cant remember all of them but I have a weak memory of me cranking the engine with the solenoid loose and the plunger stayed in place all the time. 

Is it possible to just pull the plunger right out? Have tried this and feels like I am going to rip the whole rubber thing in pieces.

Any other theories?
Car is in really good condition with only 25000 miles on the clock so we could exclude piston ring wear.
 

[Dave]

The car will run on 3 cylinders, take an injector line off and reposition it so its sticking up, and put the injector on the end - this means you'll visibly be able to see if its firing.

Try starting the car again and look to see if the injector stops firing when it dies. I suspect it will this sounds like a fuel issue.

Run a dedicated line to the pump with prime bulb, start and prime bulb at same time see if it runs for longer. If so then your fuel feed to pump is the issue. If it still dies then your pump is the problem.

[Robert Gladh]

Ok many thanks for your help, have to wait untill next weekend to test this

Have tried to bypass the fuel filter with a separate line directly from a bottle, will it make so much difference with a priming bulb? Will try this again!

Im quite suspicious to the solenoid, I have the one with 3 cabels in a shrink tubing. 
Will try to find another one with two cabels so I can change between them and maybe arrange my own solenoid function to cut the fuel and stop the car.

[Robert Gladh]

The car will run on 3 cylinders, take an injector line off and reposition it so its sticking up, and put the injector on the end - this means you'll visibly be able to see if its firing.

Try starting the car again and look to see if the injector stops firing when it dies. I suspect it will this sounds like a fuel issue.

Run a dedicated line to the pump with prime bulb, start and prime bulb at same time see if it runs for longer. If so then your fuel feed to pump is the issue. If it still dies then your pump is the problem.

Ok have been checking some things this weekend. Went back to basic and started with locking the engine, the crank, camshaft and pump is 100 % perfect.

Removed the outlet from the filter and filled a bottle with diesel, no bubbles at all was exiting the tube - No airleak before filter in other words.

Then tried to crank the engine while one fuelline was off from the pump, only a small amount of diesel was coming. Think we are geting close to the problem right? Should also mention that this was while the plunger was removed. As i said in my first post, last time the car was running was when we had used compressed air in the hole that the plunger sits in. Is there something in my pump that blocks the way? Have found another lucas pump, actually a whole engine for 150 €, is it worth considering to change the shitty pump for another shitty pump or is it better to go bosch? 
What could be wrong with my pump? The problem seems to come and go because there was fuel coming from the end of all of the four fuel lines yesterday.

There seems that there is two separate coils on my pump, the normal immobilizer one and then another one that looks like a injector in the bottom, what does that thing? Attached on picture below.

As you way find out while looking on the picture the new one is of a different model than the old one... But what does this thing do, can blow through it without any problem.

[Robert Gladh]

Ok update! Car runs!!!!!

Removed the cables from the solenoid above (NOT THE IMMOBILIZER) and the car runs great but it pours out fuel from the pump somewhere, and i cant find where. Will ask a friend to come over and let him bring his swimming goggles to take a dive in the engine bay.

BUT, my question still is, what kind of solenoid have I deactivated?

Before i was noticing the leak... No the swing in the background is not a chinese loveswing, its for my daughter..
https://www.youtube.com/watch?v=Wf62mfA47lc

Take a look at the pissing, could the deactivation of the sensor resulted in a blown gasket?
https://www.youtube.com/watch?v=-qhxViWvsl8

[Robert Gladh]

Ok update! Car runs!!!!!

Removed the cables from the solenoid above (NOT THE IMMOBILIZER) and the car runs great but it pours out fuel from the pump somewhere, and i cant find where. Will ask a friend to come over and let him bring his swimming goggles to take a dive in the engine bay.

BUT, my question still is, what kind of solenoid have I deactivated?

Before i was noticing the leak... No the swing in the background is not a chinese loveswing, its for my daughter..
https://www.youtube.com/watch?v=Wf62mfA47lc

Take a look at the pissing, could the deactivation of the sensor resulted in a blown gasket?
https://www.youtube.com/watch?v=-qhxViWvsl8

False alarm, the leak was caused by myself. Totaly missed that the bolt that held the cable to solenoid no2 was straight through in to the pump. 

I also put the plunger back = car was dead again. I have checked plunger so man Times, works perfectly outside but has to be the problem

[Dave]

Sorry only just seen these replies, sounds like you've isolated your issue there mate, good work

[Robert Gladh]

Ok, think that I will need to sum all these things up.

Car was able to start and run finewhen the screw was forgotten, a nice stream of diesel was spraying the enginebay at the same time.

I thought that I finally found the problem, air in the pump so I returned the screw for the earth connention on the fuel advance solenoid and also attached the plunger in to the stop solenoid again. Jumped in the car, put in the code, voila.. Car didnt start again.

Removed the stop solenoid plunger, still dead.

Removed the screw for the earth point on stop solenoid so it was a straight trough hole into the pump again, still dead.

Then bought another engine with a lucas pump for spares and got a tip from a guy on a swedish forum that i should check the non-return valve in the return line. It was completely stuck, both ways. Changed to my spare and car runs fine since then

Thank you Dave for all your inputs, really really appreciated