Fuel Stutter Sorted

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Mav96

Well-known member
Joined
Mar 9, 2014
Messages
437
This is my story.

So for a long time my Mav had a what seemed like fuel starvation or blockage ?
The engine would be hesitant at certain times, you could back off or accelerate through this glitch & wait for it to happen again. When it got really bad & I mean BAD I decided it was time to do something.

First step change fuel filter no change (no mini filter on mine) put clear fuel pipes connecting to filter to check for air bubbles, all good.

2nd step got 2 bottles of injector cleaner, filled up the filter & ran that through as it says on the bottle, the other bottle went in the tank. Things improved but still not good.

Step 3 remove rusty fuel pipes & replace with rubber fuel hose. (while doing this I also changed the break pipes.
<a href='https://postimg.org/image/umj477ps9/' target='_blank'><img src='https://s20.postimg.org/umj477ps9/Old_Pipework_-_20160503_135744.jpg' border='0' alt='postimage'/></a>

Step 4 I was starting to think it may be electrical ?
Removed accelerator pedal cleaned & sprayed, checked & cleaned Maf again, rewired my Cps mod just for ease of mind but you guessed it no change.

Now after all that it was just as it was originally. Now after Rick's comments on various posts saying about the pumps have issues with worn springs? (mine is Zexel) I resigned myself that this was how it was going to be.

Many Months later
The Fix
At my last MOT I was talking to the that did it I asked him if there was anything that may need attention soon, all he said was that the top of the fuel tank was wet, he was not sure if this was diesel or water as just before the mot I had been down the lanes for a thrashing so got a bit wet & muddy.

It turns out I had a little rust problem around where the fuel sensor &pipes are. Cleaned rust up, Now my O ring is pretty flat looking & pitted (unclear if thats by design)
<a href='https://postimg.org/image/xfcbr8q4p/' target='_blank'><img src='https://s20.postimg.org/xfcbr8q4p/20170529_100909.jpg' border='0' alt='postimage'/></a>
I did not have another so used gasket sealant for temp fix, Yep you guessed right again I am now driving with no fuel issues the only other thing I did was spray the electrics connector with contact cleaner but then I done that before

I have now fitted a new O ring not original but doing its job


I can only assume this effects return pressure to the tank & that was my problem all along. It has been 4 weeks now with no problems.:clap
of course I could be talking out my a**e as I know nothing. but a result is a result.
 
Great news... Lets hope that is it... On Suz's T2, I get a hiss when I remove the fuel cap, but I never do on my one. I have heard the fuel cap not sealing properly can cause running issues, so there could be mileage in your diagnosis.
 
i can run my terry with the fuel cap a bit loose without any probs just a bit of splash out.
 
So could it be water ingress and it's water in the fuel or aeration of some sort ?
 
There was no water in fuel, the seal was bad. It only got sorted because of the rust expanded making a larger gap to allow diesel to escape when splashing around in the tank. The O ring is supposed to be renewed each time you remove it. So it was probably me trying to fix my erratic fuel gauge many moons ago that started it off & caused another problem. I have no other explanation for the cure as I did nothing else. What I can say is that for 4 weeks now every time I drive my Mav I marvel at how well it drives like a different truck :clap
 

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