D2 td5 fuel pump issues??

Davyd8899 · Oct 22, 2022

Bit of a long winded 1 this so please bear with me.....

I've noticed that my fuel pump is starting to squel a little in the morning and it doesn't start first time. Fires and stops immediately. So I'm guessing the fuel pump is on its way out, however I'm having other symptoms and I'm wondering if these all point to fuel pump or if I could have another issue.

Every now and then for no reason under normal driving it'll miss for a couple of seconds and then run normal again. There is no regular pattern, it can do it at any time while driving, however I've noticed that it will do it more frequently under heavier load, ie going up hill. I've actually stopped the engine while it's missing and tried to start again and the best way I can describe it is its like trying to start it with a load of easy start in the air intake, as if 1 if the pistons is full of something, it does eventually start and after a second or 2 runs fine again. Next up is the diesel in the tank is getting super hot, to the point that when I diesel up, it emits alot of smoke/steam (or whatever it is!) Out of the fuel filler as the diesel hits the tank and mixes with the hot diesel in there. Also after a long run the filter and housing is that hot you can bearly stand to touch it.

I have already changed the filter housing, filter and injection harness. No head gasket issues and definitely no diesel mixing with the oil so I've ruled out injector seals.

So could all these symptoms point to the fuel pump or do I have other issues going on?

All advise much appreciated!!

Stanleysteamer · Oct 22, 2022

Davyd8899 said:
Bit of a long winded 1 this so please bear with me.....

I've noticed that my fuel pump is starting to squel a little in the morning and it doesn't start first time. Fires and stops immediately. So I'm guessing the fuel pump is on its way out, however I'm having other symptoms and I'm wondering if these all point to fuel pump or if I could have another issue.

Every now and then for no reason under normal driving it'll miss for a couple of seconds and then run normal again. There is no regular pattern, it can do it at any time while driving, however I've noticed that it will do it more frequently under heavier load, ie going up hill. I've actually stopped the engine while it's missing and tried to start again and the best way I can describe it is its like trying to start it with a load of easy start in the air intake, as if 1 if the pistons is full of something, it does eventually start and after a second or 2 runs fine again. Next up is the diesel in the tank is getting super hot, to the point that when I diesel up, it emits alot of smoke/steam (or whatever it is!) Out of the fuel filler as the diesel hits the tank and mixes with the hot diesel in there. Also after a long run the filter and housing is that hot you can bearly stand to touch it.

I have already changed the filter housing, filter and injection harness. No head gasket issues and definitely no diesel mixing with the oil so I've ruled out injector seals.

So could all these symptoms point to the fuel pump or do I have other issues going on?

All advise much appreciated!!

If your diesel is actually getting hot you have a serious problem and should get it fixed immediately.
the last thing we want to read is how your truck went up in smoke!
I can only imagine the fuel pump is getting hot and being cooled by the diesel, sort of.
NEVER heard of this before.

sierrafery · Oct 22, 2022

Davyd8899 said:
No head gasket issues and definitely no diesel mixing with the oil so I've ruled out injector seals.

You ruled out only the injector o-rings which would not cause any driveability issues other than diluting the oil untill it exeeds it's level eventually. Starting and running issues can be caused by the copper wahers if they let combustion gas into the fuel rail and the back pressure distubes the fuel supply and that's not visible. run a 5 pedal purge trick before you want to start it and if it starts right away after that the washers are suspects... if the holes in the air bleed valve(rear outer port of the filter housing, p/n WJN500110, replace it as first step) are full of black muck means that combustion gas got into the fuel so replace the copper washers ASAP

Davyd8899 said:
the diesel in the tank is getting super hot, to the point that when I diesel up, it emits alot of smoke/steam (or whatever it is!)

if you have the cylinder type fuel cooler it's possible that the thermostat in it is stuck closed so the coolant doesnt circulate through it hence the fuel is not cooled. Not very common but happens, the thermostat is not available as spare it's part of the cooler but you can remove it completely and let it so.

from the WSM:

Stanleysteamer · Oct 22, 2022

sierrafery said:
You ruled out only the injector o-rings which would not cause any driveability issues other than diluting the oil untill it exeeds it's level eventually. Starting and running issues can be caused by the copper wahers if they let combustion gas into the fuel rail and the back pressure distubes the fuel supply and that's not visible. run a 5 pedal purge trick before you want to start it and if it starts right away after that the washers are suspects... if the holes in the air bleed valve(rear outer port of the filter housing, p/n WJN500110, replace it as first step) are full of black muck means that combustion gas got into the fuel so replace the copper washers ASAP
if you have the cylinder type fuel cooler it's possible that the thermostat in it is stuck closed so the coolant doesnt circulate through it hence the fuel is not cooled. Not very common but happens, the thermostat is not available as spare it's part of the cooler but you can remove it completely and let it so.

from the WSM:

View attachment 276573

Well done, and you have managed to make me feel like a right D head at the same time.

D2 td5 fuel pump issues??

Davyd8899

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Stanleysteamer

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sierrafery

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Stanleysteamer

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