Outer Limits 4x4 Board

Hi there on the way back from the coast the other day the patrol suddenly started coughing and spluttering and I couldn't get more than 1600 RPM out of it...very slow trip back to Stanthorpe I can tell you! I drained the fuel when I got home and it looked fine, no water or sludge...diesel filter seems fine and it's pumping through to there alright. Hoping it's not the injectors or fuel pump.....any ideas? thanx
p.s it's a non turbo 1990 model, also is it safe to blow compressed air back through the line from the fuel filter, no one way valves or anything?
thanx

first of all check your gauze filter under the inlet banjo fitting on the pump.. ask a diesel mech if your not sure how. then replace your primary fuel filter and blow out the lines. if that doesn't help then have a look at the inlet side of things and check you havent sucked something down the snorkel and that your filters not blocked. if that still doesnt fix it the i dare say you will need a new pump.

http://www.outerlimits4x4.com/ftopic760 ... ble+filter
http://www.outerlimits4x4.com/ftopic153203.php

hopefully that will help you

thanx heaps Thomo

No problem mate.. let me know if it works

Well it seems I have a fuel pump that some lazy phuck has removed the filter and left it open....why someone would do this is totaly beyond me. It's like some old bodge mech trick to get another few thousand K's out of it. "yeah mate, you just take the inlet filter out and sell it to some poor mug" guess that mug is me. Hardly surprising considering the bodge jobs I've had to repair so far....so maybe the pump is blocked? is this an "attempt yourself job" if you're maticulous and careful or replace with another one? can't afford a rebuild if it's around $1200
thanx for all the advice...handy info for the future

That guaze filter before the injector pump is not in all of them form the factory. So if though the previouse owner was dodgy, this may not be one of them.
Check for any air leaks in your system, replace the fuel filter.

I wouldn't go trying to clean the pump.. there may be something you can flush it with but don't go pulling it apart.. you just have to go and have a look at a pump specialist and see all the special tools, test benches ect. that are required.. replacing the pump wouldn't be to harder job.. just make sure you get the timing right.

Lubro Moly Diesel Purge works a treat. You can follow the directions on this VW forum (same type of pump as in the Patol): http://forums.tdiclub.com/showthread.php?t=87948. Or you can be lazy like me and just fill you fuel filter full of the stuff and run. You won't get as good of a cleaning this way but it will be enough to clean up any fouled injectors and your pump a bit.

Tomo_89 wrote:I wouldn't go trying to clean the pump.. there may be something you can flush it with but don't go pulling it apart.. you just have to go and have a look at a pump specialist and see all the special tools, test benches ect. that are required.. replacing the pump wouldn't be to harder job.. just make sure you get the timing right.

Its not just the tools and the knowledge - its also the cleanliness - pretty much need a dedicated 'clean room'

Another thought is you could have air leaking into your fuel system. Have you checked for air at the bleeder and the injectors when it is acting up. It doesn't take much air to cause problems.

yeah have checked all the hoses...it's just the way it happened suddenly too like something got blocked. I put compressed air through the lines, drained the tank and put new fuel in, put a new fuel filter in and bled the system...seems to have had some effect not back to full power but definately better. I'll look into that injector cleaner, out of desperation I even added about 2-3% unleaded after reading threads about its cleaning powers.....thanx for all the advice