fault code power loss under load

[badger]

in the open

 

[badger]

inside of the valve, the spring on the old one was compressed to about half the lengh, also ball bearing on old one, was noticably pitted.

now fitted, and the good news is all ok.

I asked the dealer for Zexel (part of the Bosch Group) if they sold many of these, answer no.
But he did then add, that they used loads, one per reconditioned injection pump!
he did say on later pumps (where cars have external pump which is pressure regulated in its self) the valve is omited and replaced with a banjo bolt with a small hole in it, but you can and they do, retro fit these!

I have found a place on the net that do an adjustable overflow valve for the complete Bosch and Zexel range, increases power mpg etc, etc.

 

[brynjdavies]

Interesting that the label is in french as well as english, does that mean that they sold loads in france?
Bryn

 

[badger]

not sure, but dealer said that these type valves were fitted to 90% of cars!
This one was identical to the VE Bosch pump one, they did have several VP type in stock, and what they refered to as restricted orafices

so to confirm, power back, no missing or hesitation no matter what RPM, starts first time no cranking, i would estimate it only half turns over before firing on all 4.
cant tell on mpg yet, would be nice, but power is great.
pulls like a train in all gears, and also allows me to pull in high gears.
seems a totaly new car.

very happy, well worth £16 inc vat.
I would recomend everyone replaces this valve, that spring is about the size of a biro spring, 100,000 miles with 15Psi pressing on it, i would shrink.
also again confirm, these loose power more when cold, as ball sticks, spring retracts.

 

[makeitfit]

Oh please please please make that fix mine
Have you got the contact details of your supplier as I bet my local factors will look daft at me if I ask them for one:doh

 

[badger]

I don’t know whether these people will post out, any Bosch dealer should be able to obtain, but the bocsh agent in Nottingham refused to sell to me as a part, at first they said the part was wrong/didn’t exist, then thay said it was dealer (bocsh) fit only as it required specialist tools, yes like a 17mm spanner and a screwdriver are no longer available to the general public!
I managed t get it in the end from this place http://www.patkins.co.uk/index.html

Still looking good, what strikes me is how much better cold starting is, no cranking fuel through, starts before you can think about it, I have to go to Worcester tomorrow to pick up a big trailer/generator, I will report back on its towing ability then.
It never seemed that bad, but I suppose it is a case of you don’t know what you never had?

 

[brynjdavies]

Hi,
Pressure regulator came this morning, got it from an agricultural factor £8.00. Success after 2 years of trying to find the fault, it now responds from 1/2 to full throtle and keeps pulling through the rev range. The regulator is 1.3 to 1.6bar and I have read they are about 1bar but it still works fine. It was throwing a dtc code of 46 and after resting ecu it has not returned only a nice 55 code. I did test the old one with compressed air and it seemed ok but clearly not.
Bryn

 

[badger]

well done, did you read up on the variable one?
looks like this may be of use to more cars, the elusive power loss faults, maybe we were all too quick to blame electronics, I was convinced it was at first the MAF, then i was chasing air in system, and even thinking it maybe the pump.
mine also has not repeated the fault code since installing.
bit of a sod to replace on 2.7, would be easy to get at with inlet manifold off, but i strugled from above and through wheel arch.

http://torkteknology.com/products.php?product=TORK-TEK-CUMMINS-ADJUSTABLE-OVERFLOW-VALVE-OFV010

for those wanting to run SVO, it maybe worth investing in the bio compatible valve, as thicker fuel will cause more pressure, i assume all figures are taken with straight diesel.

 

[makeitfit]

Mine arrived today
Took the old one out in a few mins and had a butchers at it, then got my glasses out the case 'cause I couldn't see anything that small:augie
Gauze was full of crap anyway, so I popped the new one in and cranked up the engine
Bugger, that aint the problem:doh
So it's back to the bloody electronics again
Hey ho

 

[brynjdavies]

Hi,
The one I got is identical in appearance to the origonal so I went for that. Likewise initially I knew it was a blocked fuel filter, changed it oh dear no better. Had to be air in diesel then and yes there were bubbles after the fuel filter so changed the filter, no better. Had to be leaking in on the pipe from the tank to filter changed it, no better. Gave up on the air and bought a maf from ebay no better. Was going abroad with the caravan so bought a propper new girling maf, no better. Came home and blanked off 's don't have to meet odd egr, no better. Couldn't read ecu because 2002 diesel don't have to meet obd standard so I bought software from a company in Aus, built an interface and could now read the ecu all things were working. Ran with the intercooler sensor removed hole blocked off, no better, had checked turbo pressure early on. I was about to bash the bits out of the cat incase it was blocked and bought an exhause gas temperature gague before I did but saw this thread and success. Still will fit the egt sometime.
I don't think running on thicker veg should alter the breaking pressure of a release valve. A restriction yes.
Bryn

 

[badger]

i had the bubbles in the pipe past fuel filter, now seems that is possibly due to cavitation in pump due to valve failing half open.

sorry it didnt work for you makefit, have you tried a tempoary blockage of the return pipe, bend in half, just give it a whiz if you dare, but dont blame me!
have you tried putting clear pipe in place of rubber, so you can see any bubbles?
what is the fault? have you read the codes?

company with variable unit state one unit for diesel one for svo, maybe rubber compound if not due to thickness.

 

[brynjdavies]

Makeitfit,
Have you done all the checks that I posted just here.
Bryn

 

[makeitfit]

Hi thanks I've done them pretty much I think.
I was just hoping for a quick fix :augie
I've done new fuel pipes to and from tank. Clear pipe off filter (new) no bubbles,egr blanked,recent No1 injector sensor doda,
I'm running bio so shouldn't have thickness issues as if SVO
I do have some wierd ecu stuff going on but the faultsyou guys described was exactly the same as I'm having:doh
So I'll be back to electronic land now

 

[badger]

you say you have done egr, you have taken the throtle plate/butterfly valve off? if not the engine will lack air to burn.
is it a intercooler one?
if you had gunge in overflow valve, it must have made its way through the pump? pump shot?
if you take off overflow pipe and put pipe in to a jar, how much fuel flow have you got?

 

[rayf3262]

you say you have done egr, you have taken the throtle plate/butterfly valve off? if not the engine will lack air to burn.
is it a intercooler one?
if you had gunge in overflow valve, it must have made its way through the pump? pump shot?
if you take off overflow pipe and put pipe in to a jar, how much fuel flow have you got?

On the last check, the speedo was working and the ECU was showing zero speed....... why put fuel in if you are not moving!

 

[makeitfit]

you say you have done egr, you have taken the throtle plate/butterfly valve off? if not the engine will lack air to burn.
is it a intercooler one?
if you had gunge in overflow valve, it must have made its way through the pump? pump shot?
if you take off overflow pipe and put pipe in to a jar, how much fuel flow have you got?

Yep removed the butterfly out of the housing and blanked off the axis holes.
It was the mini gauze filter in the relief valve that was bunged up.
I've got a few days off now so will oik out the speedo and do continuity check on VSS wire to ecu. Cant wait:doh
Yes intercooler