PJ-PK Common Faults!

After many years modifying and fixing these awesome little utes we have compiled a little check list of common issues they suffer from. Most of which are easily fixed.

We will continue to add to this list as time goes on 

SYMPTOM: Crank no start, no engine light or glow plug light on dash
Cause: Dead ECU, as these utes get older we see it more and more often, what used to be 1 a year is now 1 every couple of months, the vehicle comes in dead as a door stop with no comms, and a crank no start.
Replacement and programming is the usual fix, though sometimes it can be a wiring or relay fault, if your ute is suffering from this issue we can help you over the phone to diagnose weather or not its the computer itself or something simpler. all you need is a multimeter. 

SYMPTOM: Low power/droney exhaust
CAUSE: Dead or intermittently failing Boost solenoid, located on the back passenger side of the engine bay, the easiest way to test is while the engine is running remove the vaccum hose that goes to the turbo actuator and check if the rod underneath drops, if it does follow onto the next check, if it doesnt then either you have a vac issue or the solenoids dead, left too long the actuator on the turbo will seize in the open position, following solenoid replacement the turbo will still not work properly, sometimes they can be freed with head and penetrant.

SYMPTOM: TAPPING/CHUFFING SOUND AND OIL/SMOKE AROUND THE ROCKER COVER AREA
CAUSE: Failed injector seals, usually between 250-280 thousand kms. The copper washers that seal the injectors to the combustion chamber have failed allowing combustion gases to escape past the injector and its upper oil seal, left too long it will eventually damage the injector seat that the washer seals against, requiring the seat to be cut or the head to be replaced if left long enough, it also makes injectors super difficult to remove, as soon as you notice the seal has failed repair it ASAP.

SYMPTOM: Hard starting, more so when hot, but runs fine once going.
CAUSE: Rail pressure relief valve or worn injectors, usually at 300+ kms the relief or the injectors themselves bypass to much fuel into the return circuit, causing the high pressure fuel pump to not build enough pressure while cranking, the ecu must see 300 bar before firing the injectors, if it cannot acheive this it will just let the engine crank until it does. check relief and injectors for excessive return flow.

SYMPTOM: Oil in coolant, no coolant in oil and not overheating.
Cause: Oil Cooler failure is common on these, due to oil pressure being higher than coolant pressure the failure only pushes oil into the coolant not vice versa, commonly this is mistaken for a head gasket issue but it rarely is. Replace the cooler and housing followed by a coolant flush.

SYMPTOM: Rattling at light throttle and lower power
Cause: Worn injectors, commonly 280ks onwards, fuel atomization is poor due to the injectors being at the end of their service life, or having been previously run with failed seals super heating the bodies, injector replacement is the only fix, engine failure is common if driven long term with poor injector spray patterns unevenly distributing fuel in the piston bowl.