To start off I just purchased this Humvee a few weeks ago and it had been sitting for 2+ years gathering dust. I have been trying to breathe life back into the old 6.2 engine ever since. (I have worked on engines and transmissions before but this is my first mechanical injection system I have worked on.)
First I removed the fuel tank and cleaned it out. Installed 2 new batteries. I have replaced the lift pump with a 6.2 lift pump I purchased from Auto Zone. The only difference seems to be the Humvee lift pump uses vacuum and the Auto Zone one does not. I have changed the fuel filter and screen. Installed new 24v glow plugs. Confirmed that they are getting 24v. Changed all 8 injectors. Changed the injection pump, also purchased from Auto Zone. I confirmed that the IP and injectors are working by removing one glow plug at a time and making sure that there is "diesel fog" coming out of the hole when turning the engine over. NOTE: I do not know if the IP timing is set properly (it probably isn't). I have tried setting the IP marks lined up, slightly advanced and slightly retarded and nothing seems to change much.
So this is what happens: I turn the engine over and it will start if I lightly press on the throttle or pull the throttle lock slightly. I will run for 5 to 10 seconds then putter out. It stops as if it is running out of fuel. After it stops I have to turn it over a couple of times then it will start up and die in the same way.
The next thing I am going to try is to go get some clear hose and put it on the return of the IP and see if any air is getting in there. I have already ruled out any pinhole leaks in the gas tank and lines leading up to the lift pump. I used a 5 gallon diesel fuel tank and fed the lift pump from the 5gal tank. The issues were still present.
Is there anything I am overlooking?
First I removed the fuel tank and cleaned it out. Installed 2 new batteries. I have replaced the lift pump with a 6.2 lift pump I purchased from Auto Zone. The only difference seems to be the Humvee lift pump uses vacuum and the Auto Zone one does not. I have changed the fuel filter and screen. Installed new 24v glow plugs. Confirmed that they are getting 24v. Changed all 8 injectors. Changed the injection pump, also purchased from Auto Zone. I confirmed that the IP and injectors are working by removing one glow plug at a time and making sure that there is "diesel fog" coming out of the hole when turning the engine over. NOTE: I do not know if the IP timing is set properly (it probably isn't). I have tried setting the IP marks lined up, slightly advanced and slightly retarded and nothing seems to change much.
So this is what happens: I turn the engine over and it will start if I lightly press on the throttle or pull the throttle lock slightly. I will run for 5 to 10 seconds then putter out. It stops as if it is running out of fuel. After it stops I have to turn it over a couple of times then it will start up and die in the same way.
The next thing I am going to try is to go get some clear hose and put it on the return of the IP and see if any air is getting in there. I have already ruled out any pinhole leaks in the gas tank and lines leading up to the lift pump. I used a 5 gallon diesel fuel tank and fed the lift pump from the 5gal tank. The issues were still present.
Is there anything I am overlooking?
