No Start Issue

[rtd16]

Hello
I am finally getting to try and start up my XJ I've been working on for a year, but it won't bark off.
I pretty much replaced everything up top (I don't mean the valve train, I mean in the engine bay - exhaust manifold/gasket, replaced all the vacuum hoses, new distributor, new fuel lines, new 4-hole injectors from K-suspension, and new fuel regulator, etc).
When installing the distributor I ensured the oil pump slot was just passed 11 and dropped the distributor around the 4 o'clock position and it seated fine with the rotor at 5 o'clock, or #1 cylinder. All electrical connections are made. Back when I did the exhaust manifold I made sure the #1 cylinder intake and exhaust valves were both closed as I barred the engine, and then left it there and marked the balancer so I'm pretty sure it was at #1 TDC when installed the distributor (I never rotated the crank after that before installing the distributor).

I hooked up a fuel pressure gage and by the time I got out of the car from cranking to check pressure it basically bled off. I believe it should hold around 40-50 psi. I 'gently' pinched the return line rubber hose and pressure bled off more slowly on the next crank. I completely pinched it and held even better but still bled down. Cranked one more time and blew the rubber return hose off the line at the fuel tank.

It seems like the regulator is just bypassing and shooting fuel back to the tank. But I would have expected it to at least stumble a little based on the pressure holding a little better and it's still not even trying to sputter. I'm hesitant to throw another regulator at it since they are kinda pricey.

Any thoughts or other troubleshooting I can do? Thanks

 

[Anak]

It would help it you specified which year and engine you are dealing with. Having a fuel pressure regulator to replace at the engine tells us you have a '95 or earlier, but that is about it.

Also, where you are could be helpful too. That might allow someone to give you an actual hand.

 

[rtd16]

Good point, sorry, it's a 1993 4.0L. I'm in upstate NY

 

[Anak]

Well, you are too far away for me to swing by and offer another FPR to test (I happen to have a few courtesy of my efforts with my '96 fuel system).

What I will suggest is that you pull the FPR you have in there and examine the seals. Varmint #1 managed to mess up the seals on his ('92, 4.0L) when he reinstalled it. A bit of lube (Molykote 55 would be ideal, but probably not worth buying just for this job) on the seals is a good idea.

 

[rtd16]

Thanks. I did pull the FPR and the inner o-ring was a little crimped, however during all of this there was never any external leakage, it seemed like the FPR was just stuck 'open' and sending fuel back to the tank. I put some lubricant on the o-ring and reinstalled. In the process snapped the factory machine screw on the hold down. Replaced that and now it leaks externally when I prime it. I think I'm just going to order a new FPR unfortunately. There's no way to exercise or test these to see if they seat again is there?

 

[bkccorp]

Verify spark. If present, attempt a shot of starting fluid at the intake. If it fires, you have a fuel delivery issue, and can proceed down that road.

 

[rtd16]

Definitely have spark, checked it with a noid light. Don't have starter fluid handy so I'll have to check that later

 

[rtd16]

Well I have updates. I used an air compressor with about 60 psi and blew into the vacuum line several times to try an cycle the FPR. I after a couple of blasts I could feel the spring and diaphragm moving inside. The leak was because the larger FPR o-ring apparently fell off when I was removing and reinstalling it. After running down to get an o-ring kit and buttoning it up I found the original laying on the water pump. But I have solid pressure now holds about 35 psi after priming.

Still wouldn't start so the only thing I could think of is timing. Pulled the #1 plug and barred the engine until I felt pressure and then looked in the plug hole to watch the cylinder come up to TDC. Checked the original mark it and it was 90degrees off. Not sure how but got everything back together and it runs.

However, runs like crap. Barely wants to stay alive at idle and is rough. Give it throttle and it runs better, let off and it either dies or really bogs out. Checked around for vacuum leaks and couldn't find any. Now I'm stumped again.

Also - anyone use the K-suspension injectors? They seem loud to me, I can hear them clicking.

 

[Anak]

Does it smell rich? It is possible you have a defective injector which is not closing.

It might be good to put a scan tool on it which will show you real time readings for the various sensors.

 

[rtd16]

Thanks again.
I need to grab an adapter for my scan tool since it is OBD 1.

 

[rtd16]

Also, I cleaned the IAC when I did all the work previously. It looks like new, but should you be able to retract it by hand. Mine is in the fully extended position and I believe new ones are not. I'm wondering if the IAC is causing issues.