Intermittent fueling issue?

[johnleddo]

Hello all ive been having some intermittent issues with my 2003 terrano tdi. Its cut out whilst driving a few times now it happened about a month ago&I got a tow home. The eml light showed for a while then went out, the fault code showing was p02b3 I've looked on the internet& dont seem to be able to find the exact code but i found a simular one that seemed to point to the injectors.

Any way following this first problem i changed the fuel filter and took out the banjo bolt with a gause filter out and cleaned that. About a month of happy motoring followed on a high of success thinking I'd fixed the problem until this morning when it cut out again!

Eml came on again so I'll find out what code is showing my bet is it will be the same issue. Only other problem with the fueling system is theres a small hole in the fuel tank &i wondered if some rust might have got in a be causing porblems but itd have to pass the fuel filter and banjo filter so not sure how likely that is?

If anyone has any thoughts or advice they would be gratefully recieved because at this stage im struggling for ideas!?

Many thanks
John

 

[Banshee]

Hello all ive been having some intermittent issues with my 2003 terrano tdi. Its cut out whilst driving a few times now it happened about a month ago&I got a tow home. The eml light showed for a while then went out, the fault code showing was p02b3 I've looked on the internet& dont seem to be able to find the exact code but i found a simular one that seemed to point to the injectors.

Any way following this first problem i changed the fuel filter and took out the banjo bolt with a gause filter out and cleaned that. About a month of happy motoring followed on a high of success thinking I'd fixed the problem until this morning when it cut out again!

Eml came on again so I'll find out what code is showing my bet is it will be the same issue. Only other problem with the fueling system is theres a small hole in the fuel tank &i wondered if some rust might have got in a be causing porblems but itd have to pass the fuel filter and banjo filter so not sure how likely that is?

If anyone has any thoughts or advice they would be gratefully recieved because at this stage im struggling for ideas!?

Many thanks
John

Hi John

I'd suggest that as a start you address the issue of the tank having a hole in it. You want the thing to be air tight as possible due to the Injector Pump working as a vacuum on these trucks.

It could be possible that if the tank has rusted to a small hole in 1 place that you can see on the outside, then there may be way worse inside, I've seen pictures of a Terrano tank that had orange peeled itself from the inside out.

If this is the case it is possible that you may have chunks of metal that have flaked off and fallen into the swirl chamber in the tank and caused a blockage at the pickup pipe.

From there work back up the the front of the truck, check the fuel lines along the chassis on the drivers side up into the engine bay behind the pump itself. While you are there, just check the injector pump visually to see if it's weeping from the head seal (this is where the 4 injector unions are on the rear end of the pump)

Check the fuel lines across the bulkhead and if you're still using the standard fuel filter, when the engine is running is it firm? You shouldn't be able to push it down at all, if you can, you need to bleed the system by pumping it until it is firm.

While you've got you're hands dirty, may as well take a sneaky peak at your injector leak off pipes too to make sure they haven't perished :thumb2

 

[johnleddo]

Great advice thanks very much. I'll take the fuel tank off this weekend and have a look in & see if theres anything obvious. Ive already replaced the metal fuel pipes at the rear with rubber upto about under the drivers seat where the metal seemed sound, all the joins are diesel tight as ive checked them for leakages.

The pump ontop of the fuel filter is hard when its running so the pressure seems ok. I'll have a look at the pump and injector leak off pipes if i can find them!

It sounds like the fuel tank peeling on the inside could be likely, fingers crossed i find something.

 

[Blocky10]

Mini filter could be blocked again then:nenau

 

[R1cho]

Everything Banshee has said but also change the fuel filter, I've had the same issue and changing the fuel filter sorted it, cheap and easy fix

 

[panelbeater]

what fuel you using

 

[johnleddo]

Its just running on straight diesel.

Ive took the tank off today&its clean on the inside. The area below the dipstick is wet with what i assume is diesel. Is this the right area for the head seal? Also what do the leak off pipes look like&where are they located?

Many thanks. John

 

[RJL Services]

it will more than likely be the leak off pipes they are on the injectors they are made of rubber below the steel injector pipe they link from one injector to the next etc from front to back also the very last one has a blanking bung most kits include one they have a habit of perishing and leaking you will need a length of leak off pipe then remove old one and cut new pipe to fit and replace them it is also worth doing the one that goes to the pump:thumb2

 

[johnleddo]

And would perished leak off pipes cause the intermittent problems I've had?

I've had a quick search about them&it seems that they are involved with the return of diesel to the tank so I'm not sure how this would cause the probems ive been getting?

 

[panelbeater]

try running with fuel filler a bit undone.see if that helps.

 

[RJL Services]

may be causing the wet area by the dipstick or like others have advised fuel filter have you tried running a injector cleaner in the fuel may be worth getting a new fuel filter and fill the filter with the cleaner then refit and try that as the cleaner will go straight to the injectors in a undiluted form

 

[Banshee]

The leaking leak off pipes shouldn't present any performance issues, the leak off's send any fuel back to the tank that hasn't been used at the injectors. If they are leaking though get them swapped sharpish as you're wasting fuel and making a mess no doubt :doh

Get yourself into any reputable motor factors and ask them for some injector leak off pipe, they should sell it by the metre, get yourself a few metres, it's always handy to keep some in the truck for those roadside emergencies.

Access is best by removing the intercooler, you'll have a real nightmare replacing the last one that goes back to the top of the injector pump, you'll just have to do your stretches real good before you start :thumbs

I always recommend that you replace the spring clips as well but not many do, I've had old ones snap in half when trying to re-use, you'll need 7-8mm ones depending on the O/D of the leak off pipe you get, this can be different per place you visit as some have braiding some don't

These are what I use and they are fantastic;
http://www.ebay.co.uk/itm/Mikalor-W...hash=item4b171ea96b:m:mqRRSm0yBoe_4SeruDe4qVw

 

[Thomas61]

I had trouble getting the Spring Clips from a local Motor Factor which I did find odd as did not think I should. So I tried a Motorbike garage and they came up trumps with more sizes than I could ever need. So worth a try if wanting to keep things local.

 

[johnleddo]

Thanks for all the suggestions I'm away for a few days now but I'll deffinately investigate the leak off pipes&replace if they are perished when i get back Putting an injector cleaner in sounds like it'd be worth a try as well.

 

[johnleddo]

So ive took the inter cooler off today in preperation for replacing the leak off pipes. Arround each injector there does seem to be diesel. Is this most likely to be coming from the leak off pipes or is there a seal on the injector that could be being bypassed by the diesel?

I have a diesel injector cleaner fluid on order so will try and flush them with that first but wondered if some diesel getting past the top of the injector could be my problem. Ive got some pictures but dont seem to be able to upload them.
Many thanks
John

 

[terranosaurusdoug]

So ive took the inter cooler off today in preperation for replacing the leak off pipes. Arround each injector there does seem to be diesel. Is this most likely to be coming from the leak off pipes or is there a seal on the injector that could be being bypassed by the diesel?

I have a diesel injector cleaner fluid on order so will try and flush them with that first but wondered if some diesel getting past the top of the injector could be my problem. Ive got some pictures but dont seem to be able to upload them.
Many thanks
John

I reckon if an injector was loose enough etc. to leak diesel then you would probably have a missfire/rough running.

 

[johnleddo]

I havent had a miss fire but ive deffinately got rough running to the point where it sometimes cuts out

 

[Mav96]

Your problems could well be fuelling issues get the leak off pipes done & the hole in the tank then replace fuel filter as others have said. When you fit the fuel filte fill it up with the injector cleaner, it helped mine.
The other 2 main culprits for erratic running problems are the Maf & Cps sensors

 

[johnleddo]

Ive had some time working on the truck over the weekend. I replaced the leak off pipes, repaied the leak in the fuel tank and re installed it and put a injector cleaner in the fuel filter, Ieven changed the maf for a spare which i had. Went to start it yesterday with fresh optimisum& it wouldn't start. Checked the primer on the filter which is deffinately working. Tried a few times and it ran for a few seconds but very rough ended up flattening the battery and re charging it a few times but couldnt get it to run. So today i tried it with some easy start and it would fire but not stay running. Once i managed to get it going with easy start and the rev off the throttle without easy start being applied, unforunately the revs began to die and wouldnt oick back up off the throttle.

I'm beging to wonder if its a fuelling issue at all could anyone point me in the direction of the cps sensor? And is there a way i can test it?

Thanks for all the help so far

 

[RJL Services]

have you cranked it with the fuel pipes on the injectors loose till you get fuel on all 4 then tightened it back you will need to get the air out and may take a bit of time as you have had a lot apart so air may still be present with the sensor on mine it was fine from cold until it got warm hope this may help also check a pipe connections are tight