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Lift pump fault

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PETE.T28 View Drop Down
Yardie
Yardie


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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 01 Jul 21 at 18:47
New pump arriving tomorrow, just to be 100% sure I have pulled the flow  and  return at the engine bay and put a container under each, primed a four times and there's diesel in each cup. Interestingly there was about 50 mil in the return and 30 ml in the flow. I'm just going to go ahead and replace the lift pump. 
Will update with results.

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Vanorak
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 01 Jul 21 at 23:07
I don't know that two pipe set up but that test result can't possibly be right so I will look forward to seeing how you get on.  Poor lift pump performance does usually result in bad starting.  Good luck! :)
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PETE.T28 View Drop Down
Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 02 Jul 21 at 21:13
Haven't got very far as new pump turned and was unbranded looks like a piece of junk supposed to be premium quality....that's GSF for you. Dropped tank old one out, looks tired and dIrty but ok.  Just to make sure I wasn't going mad I uncoupled the flow and return on the 05 camper filter and when primed fuel only comes out the flow....,
The 09 sportline doesn't appear to have a fuel cooler unless it's moved somewhere else it's def not in the usual place. So now have to source a decent lift pump as not fitting the GSF one it's going back,
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 03 Jul 21 at 09:15
Looks like success to me. Smile  Another one to remember!
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PETE.T28 View Drop Down
Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 08 Jul 21 at 07:38
Well got the new pump in before the footy last night and primed the system there is now a good flow of diesel from the flow pipe at the filter and minimal fuel from the return. The van fired up and seems to be smother, so test drive tonight to see if it's fixed....
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PETE.T28 View Drop Down
Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 15 Jul 21 at 21:33
just thought I would give an update after changing the tandem pump, fuel filter, lift pump....diddly squat broke down again today so back to the drawing board...



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Post Options Post Options   Thanks (0) Thanks(0)   Quote gregozedobe Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 21 at 04:41
Bugger !   I hope you find the source of the problem soon.  If you can't it might be time to get a fresh set of eyes to see if they can find it.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 21 at 09:00
Oh no!  Is the fuel flow behaving itself this time though?  Or has it gone back to coming out of both the flow and the return like with the old pump?
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PETE.T28 View Drop Down
Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 17 Jul 21 at 16:14
the fuel is only coming out of the flow now so that's all good. I replaced the starter and fuel pump relay no change. Next move is prob look at egr valve.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 17 Jul 21 at 21:50
When you say it 'broke down' what did it actually do?  Did it stop under load or refuse to start?  Are there any other odd symptoms like hissing when you take the fuel cap off?   
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PETE.T28 View Drop Down
Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jul 21 at 09:21
just to add to the misery I'm now getting battery issues. It loses all its charge overnight, had it tested by motabitz and they rekon it's okay. Have pulled the fuse on the stereo equipment but it's not that. The alternator is pushing 14.6 volts. 
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PETE.T28 View Drop Down
Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jul 21 at 11:12
Originally posted by T5 TDI T5 TDI wrote:

When you say it 'broke down' what did it actually do?  Did it stop under load or refuse to start?  Are there any other odd symptoms like hissing when you take the fuel cap off?   
slight hiss when fuel cap released so left it loose to see if it made a difference.
Same as before stuttering then cuts out and takes loads of cranking to start again. Always happens on a 4 ish mile plus journey when engine is up to normal operating temp.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jul 21 at 18:48
There is small chance that at your fairly big mileage the bad starting is caused by cracks in the head where the fuel gallery runs.  This would result in diesel getting into the oil (same as with leaking injector seals) so the oil level should rise and the oil might smell of diesel.  From the few cases I have heard about, the main complaint is long cranking to start since the cracks can introduce air.  I think you need some pretty specialist kit to pressure test the head for fuel gallery cracks.  

You could see if parking facing downhill improves the starting.  What this proves is that it is a fuel problem rather than an electrical problem.  Downhill parking can improve starting caused by a faulty lift pump for instance simply because it improves the fuel flow.     
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PETE.T28 View Drop Down
Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jul 21 at 21:42
good call, I always thought that was on the older vans axd & axe. Oil level consistent just needs a top up every now and again. Never increases or smells of diesel when I change it. Charged battery but left off the vehicle tonight will check in the morning to see if it's gone flat on its own....
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Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 22 Jul 21 at 18:21
well battery drain is intermittent, need to look more into that one. Think I have another problem developing... a few random pops from the top end so might be new cam time, maybe this is linked to the rough running!
Any recommendations in ferndown dorset area for capable mechanic....

Cheers


Edited by PETE.T28 - 22 Jul 21 at 18:21
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Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 29 Jul 21 at 20:57
Update ...
When I heard the popping noise from the top end I immediately thought camshaft but its a very irregular popping so I'm thinking injector  Had fault codes come up. Cyl 5 misfire, maf sensor, glow plug and some code uil. ..can't remember  now. Put a new maf in and all I get now is Cyl 5 misfire and that's after a 10 mile run and she starts to run a bit rough. Am I right in saying if it was an injector fault she would run rough from cold start and nothe when she gets hot?  Otherwise I'm thinking injector loom replacement...

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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 21 at 09:23
I think I would still check the cam first if it is popping at at all.  The popping can come and go hot or cold.  Usually they knock worse when cold and improve when warm but not always. 

Re the injector- I think it depends on what is wrong.  But the few I have seen misfire hot or cold.
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PETE.T28 View Drop Down
Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 20 Sep 21 at 19:52
Bit slow fixing the van, have been using the Camper for work...
I took the van for mot and the mechanic there said it sounds like an injector chuffing. So could be the loom or injector on cyl 5.
I plan to strip the front end off next week and have a look. 
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Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PETE.T28 Quote  Post ReplyReply Direct Link To This Post Posted: 22 Sep 21 at 18:26
I should prob start a new thread on injector looms but if anyone picks up this post Ive removed the rocker cover and the cam has a little bit of wear with a few lobes sharp on the edge s lost their chamfer is that bad? Can't really see the buckets...
I want to change the loom but I'm struggling to even disconnect the injectors. Can anyone just go through disconnecting the loom and how to Unplug and remove without taking the bearing cap off.

Thanks
Pete
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