Thread: Td5 interesting problem solved

Originally Posted by justinc

Hello all.
I think that I must be getting the lions share of strange and unusual problems lately.
Have a '02 D2 towed in with a noisy fuel pump, and no starting/ low or no fuel pressure. A Classic 'faulty fuel sender unit, car must be out of diesel' sort of thing.
It also had a leaking fuel block, a R/Cover oil leak and a coolant leak from a core plug, due for a service etc.
Service said vehicle, rectify oil leak, rectify coolant leak, remove pump from tank and discover tank is 3/4 full. Suddenly the screaming aerated fuel system noise isn't as straightforward as first thought. Fit another pump, bleed system and vehicle starts! Test drive about 3klm and vehicle misses then stops accompanied by aerated screaming fuel pump noises. (Note: Better get to the bottom of this before new pump is ruined)
Have a cup of Coffee and think about symptoms and when they occur. The only way air can infiltrate the fuel rail is through an air leak between the fuel pump and the fuel block, or an unpleasant scenario like combustion gasses leaking into the fuel system...
Option A is struck off due to zero fuel leaks anywhere in the system, so I set about removing injectors in the hope of seeing a damaged copper sealing washer.( I hope.)
It was then I remembered seeing a strange greyish scum all over the inside of the fuel filler cap while listening in the tank on the side of the road earlier. This is strange, thought I. So now, when I thought about it, It could be diesel carbon/ soot. This also appeared all over the fuel pump assembly- the white plastic is actually stained a shade of grey with it.
On removing all the injectors, all the copper sealing washers looked fine END ON. BUT, number 3 injector had a burnt gas track UNDER the copper washer, (between the injector body and the washer. )and rendered the injector useless. It looks like a tiny person with a small oxy set has run a gouging tip across the sealing surface! The combustion gasses have then burnt there way out into the fuel well surrounding the injector body and aerated the fuel in the head and hence the screaming pump and the higher than normal temperature of the fuel filter.
I have a photo on my phone of the offending parts, and will try and send them to Matt Rovercare to post up...

Always expect the unexpected!!!

JC

(Just viewed the photos I took. Time to get a decent camera... I'll have to re take them later)

Originally Posted by justinc

Hello all.
, and will try and send them to Matt Rovercare to post up...


JC

Thank god matt rovercare didn't take the photos with his phone carmera thingy

Originally Posted by justinc

(Just viewed the photos I took. Time to get a decent camera... I'll have to re take them later)

Send 'em on through

Originally Posted by Disco_owner

Thank god matt rovercare didn't take the photos with his phone carmera thingy

Leave my karma alone

Originally Posted by rovercare

Leave my karma alone

Oh no!!
Your Karma has run over my Dogma

Originally Posted by justinc

Hello all.
I think that I must be getting the lions share of strange and unusual problems lately.
Have a '02 D2 towed in with a noisy fuel pump, and no starting/ low or no fuel pressure. A Classic 'faulty fuel sender unit, car must be out of diesel' sort of thing.
It also had a leaking fuel block, a R/Cover oil leak and a coolant leak from a core plug, due for a service etc.
Service said vehicle, rectify oil leak, rectify coolant leak, remove pump from tank and discover tank is 3/4 full. Suddenly the screaming aerated fuel system noise isn't as straightforward as first thought. Fit another pump, bleed system and vehicle starts! Test drive about 3klm and vehicle misses then stops accompanied by aerated screaming fuel pump noises. (Note: Better get to the bottom of this before new pump is ruined)
Have a cup of Coffee and think about symptoms and when they occur. The only way air can infiltrate the fuel rail is through an air leak between the fuel pump and the fuel block, or an unpleasant scenario like combustion gasses leaking into the fuel system...
Option A is struck off due to zero fuel leaks anywhere in the system, so I set about removing injectors in the hope of seeing a damaged copper sealing washer.( I hope.)
It was then I remembered seeing a strange greyish scum all over the inside of the fuel filler cap while listening in the tank on the side of the road earlier. This is strange, thought I. So now, when I thought about it, It could be diesel carbon/ soot. This also appeared all over the fuel pump assembly- the white plastic is actually stained a shade of grey with it.
On removing all the injectors, all the copper sealing washers looked fine END ON. BUT, number 3 injector had a burnt gas track UNDER the copper washer, (between the injector body and the washer. )and rendered the injector useless. It looks like a tiny person with a small oxy set has run a gouging tip across the sealing surface! The combustion gasses have then burnt there way out into the fuel well surrounding the injector body and aerated the fuel in the head and hence the screaming pump and the higher than normal temperature of the fuel filter.
I have a photo on my phone of the offending parts, and will try and send them to Matt Rovercare to post up...

Always expect the unexpected!!!

JC

Justin, there is another way to have these symptons, if you forget to remove that O ring type washer in the centre of the fuel filter from the filter housing, i have done this and got those symptons of the screaming fuel pump and stalling

I couldn't find a smiley for giving myself an uppercut

Baz.

Originally Posted by justinc

<snip>

all the copper sealing washers looked fine END ON. BUT, number 3 injector had a burnt gas track UNDER the copper washer, (between the injector body and the washer. )and rendered the injector useless.

<snip>

JC

Was tipped off to a scenario recently where air was getting drawn into the cylinders past the injectors and creating merry hell with engine wear as it was obviously unfiltered.
Wouldn't have though it possible, but it happened.

Hi JustinC,
Another great tip. Thanks for sharing it with us on the site.

If I was in Tassie (too cold for me though) I would have you looking after my pride & joy D2 TD5 for me.

Regards,
BradM