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Topic: How to change my fuel shutdown solenoid on my Detroit 8.2ltr  (Read 1273 times) previous topic - next topic

How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Hya all , sorry haven't been online for a while , my brother passed away in January age 59 then my parents both nearly 90 had falls and hospitalised I haven't really had time to do anything else ,anyway getting back to my fuel solenoid I've got a new one ready to change I bought it off diesel pro power,I've bench tested and it's ok , has anyone ever done this job or know of anyone that has changed the fuel solenoid , looking at it on the fuel governer there is just 2 bolts to hold it in place ,but I'm not sure if I have to remove the fuel governer cover aswell , I know it says in the manual to make sure that when fitting a new solenoid to energise it first so it is retracted , obviously I can't energise the old one because it's finally give up the ghost , they say in the book that if it's fitted and not retracted then I could end up locking it in full fuel position , as it is now it is broken in no fuel position ,so energising it is not an option ,so I really am not  sure on this one  at all ,see I'm thinking if it's in no fuel position at the moment ,then undo the 2 securing bolts of the solenoid , dose it just come out as simple as that , is it that simple? ,the book doesn't really explain it that clearly or maybe it does and I'm not understanding it , any help would appreciate thanks kev
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #1 –
Don't know for sure on the 8.2, but on the 3208 Caterpillar if you take off the fuel solenoid it will run. From your description it sounds just like your solenoid. The plunger is extended, which turns off the fuel. When you put 12 volts to it the plunger retracts which allows the fuel to flow. Hope this helps. And yes I believe just the 2 bolts are what needs to be removed.
previous 1984 35 ft ORED 250 HP 3208 Cat       
previous 1998 40 ft U295 CAI 325 hp Cummins
previous 2003 40 Ft u320 build #6140 450 Cummins M11.                                                         
1999 Mazda Miata
Ron, Nancy, Tipper the cat, Max The dog
1997 U 270 36 ft build number 5174 8.3 Cummins

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #2 –
Quote from: red tractor –
Don't know for sure on the 8.2, but on the 3208 Caterpillar if you take off the fuel solenoid it will run. From your description it sounds just like your solenoid. The plunger is extended, which turns off the fuel. When you put 12 volts to it the plunger retracts which allows the fuel to flow. Hope this helps. And yes I believe just the 2 bolts are what needs to be removed.
Ah brilliant thanks for that mate ,I was looking in the book and it never really explained it properly I just didn't understand it , mutch appreciated  kev
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #3 –
Quote from: kevo0000 –
Ah brilliant thanks for that mate ,I was looking in the book and it never really explained it properly I just didn't understand it , mutch appreciated  kev
well I've just took the old one out, like you said very simple no problem , hopefully should have it running soon ,IL let ya know, kev
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #4 –
Quote from: kevo0000 –
well I've just took the old one out, like you said very simple no problem , hopefully should have it running soon ,IL let ya know, kev
well ,just an update on my new fuel solenoid , I removed the old one no problem ,connected up the new one to the wiring ,and the new one wouldn't retract just sparked , couldn't understand why cause the day before I checked the wiring with a volt meter , showing 12 volts , but I just couldn't get it to work , the only other thing I did today was check the continuity between the positive and negative terminals with ignition off, and there was continuity between the 2 wires ,so that tells me that something isn't right , a positive and a negative wire are 2 separate wires ,  anyway what I had to do temporarily was to connect a new live feed which I took from the starter motor and connected the plug together and it worked absolutely fine , was able to fit it once retracted  ,went to the front and it started straight away , and engine was  running  fine , only thing is now just until I receive the new wiring that I've ordered ,I have to switch it off by separating the plug ,  and I'm gonna run the new wire direct to a new  heavy duty switch and a 20 amp fuse, that problem is solved , however I still now have a live wire which obviously I have taped over so it doesn't earth out on anything , I tried disconnecting the fuel solenoid wire from the ignition switch , but that didn't help me because there are other things running off that same wire I believe from looking at the wiring diagrams, so I really am confused a bit now as to why this has happened ,I've never come across anything like this in my life and I'm usually am pretty good at working out a problem
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #5 –
Quote from: kevo0000 –
today was check the continuity between the positive and negative terminals with ignition off, and there was continuity between the 2 wires ,
Quote from: kevo0000 –
I tried disconnecting the fuel solenoid wire from the ignition switch , but that didn't help me because there are other things running off that same wire

You answered your own question.  Your getting continuity on the two wires because the other items are completing the circuit. 

Have you taken a test light to see if you have 12 volts when you turn the ignition on?
2014 ih45  (4th Foretravel owned)
 1997 36' U295 Sold in 2020, owned for 19 years
  U240 36' Sold to insurance company after melting in garage fire
    33' Foretravel on Dodge Chassis  Sold very long time ago

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #6 –
Quote from: turbojack –
You answered your own question.  Your getting continuity on the two wires because the other items are completing the circuit. 

Have you taken a test light to see if you have 12 volts when you turn the ignition on?
Hya thanks for input, I haven't put a test light on it ,I have used a volt meter and that is showing 12 volts, so normally when something is reading 12 volts that tells me there is nothing wrong with the wiring ,  however I have had this problem on and off for the last couple of years , i can start vehicle sometimes and it will run absolutely fine , I can switch it off ,come back the next day ,engine won't start ,the solenoid is hot, and yet then once it cools down I can try to start the engine again and it's fine , it might be fine for a couple of weeks ,and then does it again at random , I just never knew  if or when it was gonna happen ,so I bought a new one ,as soon as it arrived I tested it on a separate battery to make sure it was ok  that was probably a month ago , then I seem to have no problem with the old solenoid since the new one arrived , until the last couple of days and that was it ,it just stopped completely and haven't been able to start it since , so I was convinced it must be the solenoid and all it's been doing is showing signs that it's on the way out until I couldn't get it to work anymore ,  that was why I finally changed it over to the new one , I was convinced once I connected the new solenoid it would work straight away, and when it didn't I was quite surprised , I will try and connect a 12 volt light tommorrow  but if that lights up no problem , then I can't understand why it won't power up the solenoid anymore,  the problem could be just staring me in the face and I just can't see it, 
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #7 –
First use the test light between the two wires and see what happens. 

Next take the test light to a good ground and then test the two wires. Do this with both key on and off.  Let us know what you find.
2014 ih45  (4th Foretravel owned)
 1997 36' U295 Sold in 2020, owned for 19 years
  U240 36' Sold to insurance company after melting in garage fire
    33' Foretravel on Dodge Chassis  Sold very long time ago

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #8 –
Quote from: turbojack –
First use the test light between the two wires and see what happens. 

Next take the test light to a good ground and then test the two wires. Do this with both key on and off.  Let us know what you find.
Ok will do ,going up to the  villa soon , and IL check that, and let you know later , I'm 6hrs in front so you won't see this till later thanks kev
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #9 –
Quote from: kevo0000 –
Ok will do ,going up to the  villa soon , and IL check that, and let you know later , I'm 6hrs in front so you won't see this till later thanks kev
Hya ,I've done the checks that you said, connected a light to the positive and ground , With ignition off , nothing as it should be , with ignition on ,the light comes on no problem ,  but when ignition off the the continuity test ,showed continuity between positive and ground , I ran a long cable from the back  to the under dash wiring and did the same continuity from positive to ground ,yes the same , that is what's really confusing me, why would a positive wire ,turn to ground when switched off , ibeill try again tommorrow and connect to the solenoid and see if it works ,  but even if it does I won't be confident that it's fixed because this problem I have had for ages intermittently,  to be honest I was hoping that when I connected the old solenoid to a separate battery that it didn't work , then I could have said yes definitely the solenoid has broken and that was causing all the problems but it did work , even the new solenoid wouldnt work on  the existing wiring ,  I will try again now the new solenoid is fitted to see now if it works or sparks and blows fuse , but at least I know that it works perfectly as it is completely off its own circuit nothing else on it.            I won't try disconnecting the original wire cause look at diagram there are other things on that same circuit, so I will just insulate the end of the wire , and secure it out of the way , everything else seems to work temperature gauges brake lights ,fog lights , reversing lights etc , even if I connect the new solenoid back to how it was and it does work ,IL never be 100% confident that it won't let me down again ,
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #10 –
You are saying that there other items on the same hot wire.  These other items are connected to the hot and ground. When you do a continuity test the circuit is being completed by going through these items to complete the circuit. If you were to disconnect the other items on the circuit and you did the continuity test it would show open.
2014 ih45  (4th Foretravel owned)
 1997 36' U295 Sold in 2020, owned for 19 years
  U240 36' Sold to insurance company after melting in garage fire
    33' Foretravel on Dodge Chassis  Sold very long time ago

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #11 –
Quote from: turbojack –
You are saying that there other items on the same hot wire.  These other items are connected to the hot and ground. When you do a continuity test the circuit is being completed by going through these items to complete the circuit. If you were to disconnect the other items on the circuit and you did the continuity test it would show open.
When you say open ,do you mean no continuity ,  kev
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #12 –
Quote from: kevo0000 –
When you say open ,do you mean no continuity ,  kev
Hya , looking at the wiring diagram the only other thing that's on that wire is the coolant temperature sensor and overheating sensor, IL try and find pic of wiring thanks kev
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #13 –
Quote from: kevo0000 –
When you say open ,do you mean no continuity , 
That is correct, no continuity. 

Yes you are completing the circuit from the circuit wire to ground through the devices on this circuit. 

If you can find where the wire to the solenoid is connected to ground, I would re make that connection.
2014 ih45  (4th Foretravel owned)
 1997 36' U295 Sold in 2020, owned for 19 years
  U240 36' Sold to insurance company after melting in garage fire
    33' Foretravel on Dodge Chassis  Sold very long time ago

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #14 –
Quote from: turbojack –
If you can find where the wire to the solenoid is connected to ground, I would re make that connection.

Or if finding where the ground wire terminates is too difficult,  just remove/disconnect the old ground wire and make a new one to a known good ground.
Brett Wolfe
EX: 1993 U240
Moderator, ForeForum 2001-
Moderator Diesel RV Club 2002-
Moderator, FMCA Forum 2009-2020
Chairman FMCA Technical Advisory Committee 2011-2020

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #15 –
Sounds like poor ground in engine compartment. Add a ground wire to an easy to snug bolt .

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #16 –
Quote from: turbojack –
That is correct, no continuity. 

Yes you are completing the circuit from the circuit wire to ground through the devices on this circuit. 

If you can find where the wire to the solenoid is connected to ground, I would re make that connection.
I have already done that ,new ground wire attached to one of brackets on engine ,  but yeah your right , whenever there is an electrical prob usually turns out to be a poor ground ,I have run several new ground wires over the years to sort out different electrical problems , , I've made new ground wires and attached to chassis virtually for all the front and rear lights and indicators over the past few years
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #17 –
Quote from: kevo0000 –
I have already done that ,new ground wire attached to one of brackets on engine ,  but yeah your right , whenever there is an electrical prob usually turns out to be a poor ground ,I have run several new ground wires over the years to sort out different electrical problems , , I've made new ground wires and attached to chassis virtually for all the front and rear lights and indicators over the past few years
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #18 –
Quote from: kevo0000 –

Looks like the only other things that are connected to that same circuit are the water temperature gauge and the over heat warning light ,and that seems to run to the alternator
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #19 –
Quote from: kevo0000 –
Looks like the only other things that are connected to that same circuit are the water temperature gauge and the over heat warning light ,and that seems to run to the alternator
Well ,just an update on my solenoid , I've fitted a new ground wire from chassis to engine , the fuel solenoid now works fine,  just waiting for the new wire to arrive and will replace , all other electrical devices are working all good and well ,thanks for everyone's input ,  kev
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo

Re: How to change my fuel shutdown solenoid on my Detroit 8.2ltr

Reply #20 –
Hya all , this fuel solenoid will be the death of me ,  after quite a few weeks of being able to start the vehicle no  problem whatsoever , has been starting first time every time , until today , I had a new ground wire from chassis ,brand new 12 guage wire running directly from the ignition , and worked fine , , now what I have discovered today by accident , is first off I went to start the vehicle , solenoid didn't click in ,I thought oh know here we go again , anyway I had this idea just came to me ,I put my foot on the gas pedal and turned ignition on and clicked and started straight away obviously as soon as I started it it gave full revs for a second and I released the pedal and it was ticking over fine no problem , I switched the engine off , then turned the ignition on ,solenoid didn't click in again , so I did the same , so every time I start the vehicle now as long as I push the foot on the pedal it will click in and start , , so it's telling me now that the problem I'm having and it's probably been the same problem I've had with it for the last 3 years , it's almost like something in the fuel governer is preventing the fuel solenoid from retracting , I know I'm gonna have to take the cover off the governer , and physically see why this is happening , it's been sutch and intermittent fault , that maybe it wasn't the electrics after all even the old solenoid works fine on a separate battery , any ideas what this could be , cause I'm getting really frustrated with this now , I was planning to take it for its test sometime in September , I don't want to risk taking on the road yet until I've sorted this problem out , any suggestions what it could be, thanks kev
1990 foretravel grandvilla, Oshkosh chassis
8.2ltr Detroit turbo