1995 L400 Diesel Engine Hesitation/Shudder/Cut Out under load

devrtyle2162

New Member
Hey everyone, I've recently picked up a 1995 L400 2.8 Diesel 4M40. Hoping you can help me diagnose a problem, I really appreciate the support these kinds of groups provide.

I seem to be having a Hesitation/Shudder/Cut Out while driving, especially under load. If I step quickly on the accelerator from stop, I notice lag, a decent plume of black smoke, and then were off. While driving, I notice this hesitation typically under more load, usually around 2-2500 rpm.

Engine starts up instantly when cold using the glow plugs (Yesterday was slightly warmer and didn't hear the plugs come on and it was a rougher start than usual). The previous owner of the vehicle had changed the Throttle Position Sensor recently to mitigate this issue with no success. I've checked the voltage of the new sensor with key on and have around 0.88V- 3.78V as you maually use the throttle and notice no dead spots. Seems like the Forums say 0.78V is ideal for these things, but I run out of adjustment to go any lower than 0.88V. It my understanding this being setup wrong would mean the car hunts for a gear at the wrong time. It doesn't seem like its hunting for a gear, it seems more like a cutout/hesitation.

The car has new batteries/alternator throwing out good voltage. I've read a bad diode can cause some stray AC to enter the system and cause problems like this, but I believe this has been ruled out.

Im personally leaning towards this being a fuel issue of some kind. Brand new fuel/air filter installed a couple weeks back (Had problem before and after new filter). I have noticed what looks like a very slight amount of weeping coming from the top of the injectors but extremely small if any, looks clean down there, no carbon buildups to see.

Im not exactly sure, where to go next. I've thought about taking the injectors out to clean them, or run a can of diesel purge through the lines, but could use whatever guidance you may be able to provide. Appreciate it guys.
 
Check the egr valve for proper operation and check for air bubbles on the fuel supply, possible there is air in the system
 
Hey guys, just thought I would make an update on the hesitation/shutter/cutout problem I was having on my 1995 L400 2.8 near the end of December (*See post for details)

One of the most common suggestions was a faulty EGR. I took mine off, cleaned it and everything seemed to be in proper working order not plugged or sticking open etc. Decided to just unplug it and cap the vac. lines as I wait for my block off plates to arrive. This didn't make any difference to the problem I was having.

I read a very informative article on the Delica fuel system here http://biopowered.co.uk/wiki/Mitsubishi_Delica_fuel_system I realized that I had not removed the upper O ring on the Donaldson P550390 filter I had put on as per Delica USA list https://www.delicausa.com/fullwidth-page-3-2/ (Can someone tell me what fuel filter you are running in Canada without having to order from overseas?) Maybe I was sucking air into my fuel system? Off goes the filter, take off the O ring, fill it with a bottle of Liqui Moly Diesel purge for good measure and bleed the system. It seemed like my problem went away and that the issue had been solved. When I went to drive the next day however, it seemed like the same problem came back. No changes.

The pressure sense line to the turbo looked in good shape, but I changed it out for good measure with new vac. line. Perhaps a hole in the line would lead my turbo waste gate to open at an improper time? (Someone can correct me here with what this line does)

I replaced all the fuel lines in the engine bay with new hose and clamps. The return line from the injector rail to the back of the injection pump was rock hard and pretty much hand loose to wiggle off. Maybe I was sucking air into the back of the pump which would be bad. If air is getting into your supply lines you will obviously have trouble. If air is getting into your return lines, should you in theory have less trouble? It seemed like since it was going back into the pump, any air would be awful.


A faulty Throttle Position Sensor was also a possibility. Upon testing voltage, all seemed very close to spec. (I understand a voltage test is not necessarily the way to do this...) Upon looking at the wiring, I found a spot where someone had scratched the coating off a random wire near the firewall. Back probe the TPS and check for simple continuity, yep, this was a wire for the TPS. I cut out the bad spot, crimped on a new piece of 18g wire (Instead of 20g wire since it was all I had on hand, someone can yell at me if this is an absolute no no). The old wire didn't seem like it was actually broken, just the coating had been scratched out. See picture. Maybe enough internal corrosion was causing a bad reading from the TPS?

Its been a few days now, and haven't noticed the pesky issue come back so i'm hoping all is well for now. Just thought id share my findings for anyone who cares to read this kind of thing in case you have the same issue sometime.

Cheers!
 
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