I have a problem with my van and just cannot get my head around it, it all started today when i took the low pressure fuel pump out ( pump in tank ) for a good old clean as it was whirring quite loud sure enough there was loads of crap in the pump, i used some fresh diesel to swirl around the pump and tip it back out i also blew down the two nozzles on top to make sure all the crap got out. Put the pump back in now the van will start then cut out, sounds like fuel deprivation or maybe air? Is there anyway i can bleed the fuel system and or any other suggestions ?

I need this van up and running for work so any reply will be greatly appreciated.

Sorry just to add the van is a 2005 model

Anyone? :bang:

The fuel system is self-bleeding. Turn the ignition on but do not start the engine. Listen carefully near the fuel tank and hear the pump circulating fuel. Wait until the sound is steady with no gurgling and air sounds. Then start the engine.

Good luck.

Thats what i did, but it didnt work I tryed to bump start it last night to no avail. It will no longer start as the battery is flat and now parked at the bottom of the street right opposite a snicket / ginnel / walkthrough. Im going to take the fuel filter off to see if thats blocked tomorrow and re-fill it then try find someone kind enough to give me a jump start ill let you know how it goes.

As you have had the pump out of the tank I would suggest you first check to see if that is pumping, just remove the inlet pipe of the filter housing and get someone to turn the ignition on whilst you hold a can or something under the filter pipe. if fuel spurts out the pump is ok, if not check the pump and its electrical feed.

Ok i took the fuel inlet off the fuel filter and twisted the key into MAR position it did squirt out diesel. I then took off the filter and checked all the holes wasn't blocked by erghh, blowing into them lol the top fine the middle fine the one closest to the bottom was blocked and still is although i cannot see what purpose it is there for?? also the middle one was slightly damaged when trying to take out the pipe to get the filter off could this be the reason? its not leaking diesel but maybe it might be sucking in air? Anyway i did manage to bump start the engine it got halfway around the block then cut out. I had to keep it at very high revs 3000 and drive like a maniac to keep it going, as soon as my foot left the pedal it cut out. The only reason i can think off is that the lift pump must be damaged although it is squirting alot of diesel out (filled a pint in a few seconds) because the problem only started when i took the pump out and cleaned it. if a pipe has a tiny hole would this cause these symptoms?

Quick update< charged battery van will run on idle as soon as i try to rev it cuts out just wondering when i took the pump out theres 8 nuts that hold it in place and 3 sheered off trying to loosen them, could this have anything to do with it? does it need a air tight seal in the tank? surely not.

Any advise will be highly appreciated.

Im going to get a lead to diagnose the van does anyone know what type of lead i will need and also where the socket is? thanks alot.

Oh dear

If the pump is full of crap then the filter is full of crap and the tank is full of crap, strip it all out from the filter back and clean and dry meticulously . Do not!!! reuse the diesel in the filter you need to be absolutely meticulous clean with changing the filter*

Is your tank rusty?

*Aside from water resuspension of particles in the filter is the main cause of premature failure in common rail:
http://www.afssociety.org/spring2011/proceedings/presentations/020-Verdegan-paper.pdf

Tank is clean no rust nothing. pump is clean and is running fine. took filter out for now since i cant get anywhere to get the filter atm, going to try bypass the filter with a piece of pipe and some clips, just to check air isnt getting in through there.

bypassed the filter left the return pipe i think (bottom one) out and it pissed diesel out all over the return plugs into the filter but doesnt fill it up? is it a dead end for that pipe? or is my filter blocked?

bypassing didnt seem to work? maybe a airleak elsewhere?

You can't do that sort of thing with common rail. The tolerances are just a couple of microns, a bit of water and your injectors and pump are stuffed in a minute do you know how much those injectors and pump are - its about 4 times cheaper to replace the whole engine from a breakers than change the pump and injectors.

That filter is in tons of vehicles doblo, ducato, multipla, punto, astra, corsa, meriva, vectra, zafira, saab 9-3 etc. etc. in other words you'll get one no problem.

The next thing to do is get a filter then check the leakoff on the injectors.

Get someone with diagnostics to check the rail pressurre when your cranking.

Engine won't even attempt to start unless your making 250-200 bar at cranking.

Ok im going to get a filter are you on about just the paper element or the housing thats fitted to loads of vehicles? Also where are the injector pipes located so i can do a makeshift leakoff test. The van does run but after a while it cuts out. all different sometimes 10seconds some times 20mins without revving

Does anyone know what type the diagnostic socket is? 2005 fiat ducato 2.8jtd ?

ashley132 said:

Does anyone know what type the diagnostic socket is? 2005 fiat ducato 2.8jtd ?

Click to expand...

OBD I had no luck with generic readers though, you can use fiatecuscan with a kkl cable from ebay for less than a tenner.

I was referring to the paper element.

No offence but if you don't know where to look for the injectors I think you should get someone else to look at the van, people can spend a fortune throwing parts and time at a problem.

Im a keen learner everyone has to start somewhere I consider my self mechanically minded to a certain extent for instance i change all my brakes, suspension ( took apart replaced strut bearings ) i service the van my self. Its just one of them things thats ive never tryed to fix so i dont know where they are if you could tell me i would be apprichative.

Also whats your verdict on this- the van starts runs then sounds rough and then cuts out, trying to restart the van it wont because the in tank pump is not running some reason turn key back off wait for 30 secs pump will run again.

could it be that the pump is cutting out while the van is running? maybe a safety device i dont know but would it give a sudden stop of the engine or a rough running then cut out?

Im going to get a in tank pump from the breakers yard tomorrow only £45 and could do with a spare.

Also thanks for the information you have already given me.

Hi
Have you checked the emergency fuel cutoff switch, located up on the firewall near the battery, maybe has a fault of some sort ?? It cuts the earth to the fuel pump which doesn't really gel with your problem as it still starts & runs for a while.
Should only cutout when there is an impact although I have heard of them activating/cutting out after hitting a large pothole or similar.
Cheers

I'd be guessing something to do with the pressure regulator on the high pressure pump possible due to dirt/debris in the pump. Could be a lot of things though rail pressure sensor, third piston deactivation solenoid, sticking injector, wiring, cam sensor / sensor gap. Diagnostic will narrow things down.

One thing you can do is disconnect the rail pressure sensor the ecu will then default to a predetermined pressure - about 470bar. If it runs fine like that then your pump and injectors are probably ok.

Heres a great document that give you an idea of how the bosch injection system operates:
http://ftp.psyborg.rpg.pl/hdi/Bosch Hdi Edc15c2 - Injection System - 153 Pp - English.doc

Got it sorted.
It needed a new lift pump even thought the one i had seemed to be running fine. Bought a fitted the new one and now runs perfect.

Thanks for all your help.