pos
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injection timing issue?
- Thread starter pos
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pos
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- West Yorkshire
Might be an idea mate... and possibly the ones on yer spill pipes
I'll do that too. I might as well do the whole shebang and fit new braided hose to the spill rail banjos too. I will double check that the filter inside the return bolt on the IP is not clogged up (it shouldn't be - it's a new pump) and that there is no air being able to find its way back into the system through the join in the return line.
If all those lift pumps are failing, and struggling, it suggests a serious obstruction to the flow between the fuel in the tank, and the lift pump, and all this part of the system is in SUCTION, so any leak is AIR INWARDS.
The very next thing to do is get the INLET pipe off the lift pump, and rig up a temporary pipe to the inlet side of the lift pump. Take this temporary pipe and shove it into a supply of clean fuel from a can, or a 3 litre plastic milk bottle, anything.
See if that makes an improvement.
If it does, start thinking about by-passing that Sedimenter thing, or cleaning the screen in the fuel pick-up in the tank, or a crushed supply pipe somewhere.
Take the fuel filler cap off then put an air line on the end of the original fuel line and give it a good puff.
Does it bubble into the fuel tank?
My money goes on a problem between the fuel in the tank, and the lift pump.
Screen on pickup pipe... pipe to sedimenter ... sedimenter unit (scrap it anyway) ... pipe to lift pump. That's the lot!
CharlesY
The very next thing to do is get the INLET pipe off the lift pump, and rig up a temporary pipe to the inlet side of the lift pump. Take this temporary pipe and shove it into a supply of clean fuel from a can, or a 3 litre plastic milk bottle, anything.
See if that makes an improvement.
If it does, start thinking about by-passing that Sedimenter thing, or cleaning the screen in the fuel pick-up in the tank, or a crushed supply pipe somewhere.
Take the fuel filler cap off then put an air line on the end of the original fuel line and give it a good puff.
Does it bubble into the fuel tank?
My money goes on a problem between the fuel in the tank, and the lift pump.
Screen on pickup pipe... pipe to sedimenter ... sedimenter unit (scrap it anyway) ... pipe to lift pump. That's the lot!
CharlesY
pos
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Cheers Charles,
I will by-pass the fuel tank and supply line to see if it makes a noticeable change. I did blow down the fuel hose with an air line about a month ago and, with the the filler cap removed, you could hear the fuel in the tank bubbling, and a nice toxic diesel vapour was escaping from the filler neck. I don't have a sedimenter installed, so that can't get in the way of things but I do think that it is possible that the rubber fuel hose between the tank and the lift pump is still drawing some air in.
Off to bed now, but I will report back tomorrow with my findings
Thanks again
-Tom
Cheers Charles,
I will by-pass the fuel tank and supply line to see if it makes a noticeable change.
I do think that it is possible that the rubber fuel hose between the tank and the lift pump is still drawing some air in.
Off to bed now, but I will report back tomorrow with my findings
Thanks again
-Tom
Me too ... ZZZZZZZZZzzzzzzzzzzzzzz............................
CharlesY
Pos, I'm having exactly the same problems as you with my 200tdi. I can see air bubbles in one of the spill off pipes which is clear. I have just rebuilt mine onto a new galv chassis, wish i'd have spoted the air bubbles before rebuilding it. My fuel lines have been cut and re-joined at some point, so I'm going to replace all of the fuel pipes with new hose and clips, I think the trick is to have as few joints as possible in the fuel lines. Also my spill off pipes are a bit shabby so I'll replace these as well, I have seen some small spring steel type clips somewhere and wondered about fitting these onto the spill pipes? Keep us posted on what you find mate, I really hope you get to the bottom of it.
pos
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I have been thinking along the lines of the return system from the pump, but I blew it clear with an airline not too long ago. I think that the tank is venting properly because there is no hiss when I remove the filler cap. There's definitely something not right somewhere
I have been thinking along the lines of the return system from the pump, but I blew it clear with an airline not too long ago. I think that the tank is venting properly because there is no hiss when I remove the filler cap. There's definitely something not right somewhere
Sounds like your problem is no return to tank causing excessive pressure as I thought 200 and 300 tdi had return to tank
There should be a return line to the tank, and not only does that return the excess fuel, it takes with it any AIR that needs disposed of from the fuel lines and pump.
Check it out carefully. I think you will find one somewhere.
CharlesY
POS was it a 4 cyl petrol engine before? as the v8 and diesel have tank returns
Oh God ..... don't tell me it's a petrol to diesel conversion and there's no return pipe ...
There MUST be a return falling free flow into the tank.
CharlesY
instantsquid
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I think some wires have got crossed. If I recall correctly it had an 19J engine in it prior to the 200tdi.
SUPER!!!
So does it retain the FUEL FILTER from the 19J setup?
If it does, and from the pics it looks like it does, take off the Banjo Bolt on the top of the filter, and have a close look at it.
Part of the threaded section should be machined down to smooth, and somewhere in that section you should find a tiny wee hole drilled right through to the middle of the hollow bolt.
That is the self-bleeding hole, which lets a lot of AIR from the insides of the filter casing escape back to the tank, and then when there is no air left, a small amount of fuel passes through.
THESE HOLES GET BLOCKED VERY EASILY, and if it is blocked, no self-bleeding will take place.
A standard cure is to drill the hole out to about 1mm or even 1.5mm, after which it will never block again.
When the fuel in the tank is LOW or the fuel sloshes around a lot, it is easy for the pick-up pipe to take in a small dose of AIR, and that self-bleeding arrangement (the wee hole in the banjo bolt) is designed to get rid of it.
Check it out.
CharlesY
pos
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Whoa! Where has all this talk of no fuel return plumbing suddenly come from? The 200tdi engine does not have a fuel return from the fuel filter housing, but it does have a return from the injection pump to the fuel tank. The spill rail from the injectors connects to a banjo bolt which is screwed into the injection pump. The opposite side of the banjo then has a length of pipe which runs back to the fuel tank, carrying leak-off fuel from the injectors, and any excess fuel from the injection pump. It is the proper 200tdi fuel return setup. I used to have a 2.5 n/a engine installed which had a return fitted to the fuel filter housing. The older cav type fuel pump did not have a built in fuel return, but instead, relied on the injector spill rail which ran back through the fuel filter and down a return line back to the fuel tank.
-Pos
-Pos
