Problems with Fuel Pump

[Hector]

Hi to all....this is my first posting (have just joined) and am very impressed with the general standard of help & advice given, soooo......
I have a Maverick 2.7TD (GLX) 1994 that has developed a problem. It won't rev above 2000 RPM regardless of what I do.
I have,

Changed the fuel filter
Checked that the fuel lines are all secure (even replaced the line from the filter housing to the pump) and clear (no leaks found)
Dismantled the fuel pump banjo fitting to check and clean the 'mini' filter in the pump itself. On that matter the spring and filter appear to have been removed by a previous owner and NOT replaced.

The car starts ok and will rev uninterrupted to 2000 RPM then just sits there.

I am an engineer by trade so hope that I have covered all the things I should have done.

One last thing, if I hold the pump open to max the revs then push down on the lift pump button the engine will surge for a moment or two by 200/300 RPM.

Starting to think there is a some sort of blockage within the pump or the pump itself is duff?? (Don't know too much about how these pumps work internally).

Any advice will be greatly appreciated as I live in the South of Spain and cannot get a garage to look at it (you can't tow a vehicle ANYWHERE in Spain).
Thanks & regards

 

[rag1873]

have you tried testing your maf unit?? i too had this problem and it turned out the maf had given up making the vehicle very sluggish, easy to replace and it was like driving a new car!!

 

[Hector]

Thanks for your help, what exactly is the maf umit (sorry, still a greenhorn)?

(10 mins later) OK Mass Air Flow........will give it a try

Thanks again

 

[Toolbox]

Unfortunately you wont find a MAF on a 1994 td model its only fitted on 96 onward tdi engines.

Have you got any smoke?

It could be a number of things that can cause your problem from the injection pump to a blocked exhaust.

To eliminate the fuel system to the pump and any blockage in the return to the tank, I would rig up a can of diesel and siphon a feed from it, using a length of tube direct to the injection pump and also fit another length of pipe from the return of the pump in to the cankeepimg the can raised above the engine.

 

[iandouglas]

fuel pump

hi hector .2.7 td DOES NOT HAVE A MAF.
IT SOUNDS LIKE ITS FUEL STARVATION , but does it have a hand throttle
if so make sure that its closed down properly on the fuel pump
if its got one you will have one throttle cable +one hand throttle cable going to lever under neath throttle operating rod.
if its not closed it will starve the pump
rgds.iandouglas

 

[rossco]

If you use the "Search" function at the top of the page you should be able to pull up previous posts on this subject and be able to sort out anything that might be of help. :wink:

 

[Hector]

Unfortunately you wont find a MAF on a 1994 td model its only fitted on 96 onward tdi engines.

Have you got any smoke?

It could be a number of things that can cause your problem from the injection pump to a blocked exhaust.

To eliminate the fuel system to the pump and any blockage in the return to the tank, I would rig up a can of diesel and siphon a feed from it, using a length of tube direct to the injection pump and also fit another length of pipe from the return of the pump in to the cankeepimg the can raised above the engine.

Thanks for that......I have actually tried feeding the pump from a canister filled with fuel with the same result ie, nothing above 2000 RPM, BUT I didn't rig up a return hose, I just left the old one in situ....will try what you've suggested, thanks a lot.

 

[Hector]

Re: fuel pump

hi hector .2.7 td DOES NOT HAVE A MAF.
IT SOUNDS LIKE ITS FUEL STARVATION , but does it have a hand throttle
if so make sure that its closed down properly on the fuel pump
if its got one you will have one throttle cable +one hand throttle cable going to lever under neath throttle operating rod.
if its not closed it will starve the pump
rgds.iandouglas

Hi Ian, thanks for your response...yes it does have a hand throttle but that is working ok with no apprent problems.

 

[Timbo_1975]

hi there, if you have tried running it with a dedicated gravity fuel supply direct to the pump with no change, and the throttle flap, if fitted is not stuck closed due to whatever reason, and the exhaust is not smoking when trying to rev, then i would say with almost total certainty that the vanes of the primary-pump have broken up inside the injector pump.

when they fail they usually wont come over about 1000rpm but yours may still be working slightly..

Tim..

 

[elty001]

injector pump

had injector pump failure recently on my 2.7 tdi.not sure what your set up is like but i was banging my head against a wall for weeks as the problem was intermittant to start with and then gradually got worse.have you checked all the wiring and sensors connected to the pump as these are the weak link.i just went through a process of trial and error for about 6 weeks until i finally got to the problem.hope you have better luck than i did as i,m now breaking it for spares as it would have cost me more to get it all sorted than the motor is worth bought a 2.4 petrol for a grand so i'm still in the terrano gang :smile:

 

[Timbo_1975]

The TD and the TDI do not have the same injection equipment, the former is entirely mechanical (better in my opinion!) and the latter a VP 30 electronically controlled pump.

Tim..