Thread: TD5 Fuel Pump & Sender

check the filter first

did you put the hoses on correctly

how are the relays and fuses, is there power getting to the pump?

my field test is to crack the filter drain and fire it up if that ejects fuel nicely then I goto the regulator block and crack that to see whats trying to get back to the tank.

Hi Dave,
Thanks for your reply.

I went ahead and soldered up the wire to the sender on the old pump, then took out the new one and put the old back in. The sender worked great as the gauge now worked, but still no sound of pump working. The old pump worked before it came out apart from sender that now works, so assume the old pump not faulty. Eventually after alot of time and fustration I looked at the relay for the pump again. I took it out to have a good look this time, but looked fine (location R1). In location R3 (headlamp powerwash according to manual) there is the very same relay, so I swaped them. Turned the ignition on after replacing the earth to battery and the pump sounded. The problem now after a few turns the battery is low, so will recharge tomorrow and hopefully starts ok.

I now have a new pump that was very noisey to me, that I believe is faulty, and ruined the relay. Should the fuse not have blown instead of the relay being ruined, if the pump is faulty.

Chris

urmmmmm yes no maybe.....

some automotive fuses allow a current of nearly double its rate for about a second and most will hold a 150% overload for up to 10 seconds plenty of time for your relays contacts to become damaged.

Once a relays contacts become pitted or burnt they degrade at an almost exponential rate.

If you're lucky you may find that the relay was so shot that it was relying on the extra current draw of the pump to warm up the contacts allowing them to make full contact and with the lower draw of the new pump they werent contacting enough.

I have to say when I first got the discovery the old pump was not really noticeable (could hear when you turned the ignition), but when I first put the new one in and tryed it, it was loud (first to coming to mind was the one was not that loud). Now with the old one back in, I am sure the new one was louder as the old one is much quiter. I think the new one is a stuffed pump.

Having read what you said (Dave) about the relay I went out and got it and now removed the outer shell. Looking at the contacts I think they might not be too bad. Really need proper day light to see. I had been reading some where else about resoldering some of the blade conections on relays as they can cause problems. I will do that and see if the bad relay will now work with the old pump and let you know.

I have been thinking about not getting it restarted tonight and how the new pump did not send any broken material through the lines and cause blockages or the like.

Chris

thats what the filters for....

Originally Posted by Blknight.aus

thats what the filters for....

I have been having a look at the fuel system component diagram and the question would be that the fuel goes by the low pressure stage to the filter and then back to the high pressure stage and then to regulator and injectors, so if the high stage had the problem could it be possible to send unwanted material before it packed in.

Hopefully when I recharge the battery it starts no problem! fingers crossed.

Thanks, Chris

Hi all,

I have recharged the battery and got it started and running great with the old and fixed sender, so I will keep the new one as a spare should the old one go sometime. Maybe it was only the relay and not the pump.

I should add that I hooked up the Nanocom and it did not detect the pump not running due to a faulty relay. It did not register any fault.

Chris

the nanocom wont pick it up directly

if it senses power going to the relay it assumes the relay is working and therefore so is the pump.

you need to check the fuel pressure and temp to actually work out what the pump is doing. (thats generic, I dont usually use the diagnostics kit to work out whats going wrong with the engine, just the accessories)