Fuel System problems ....But my problems with acceleration had not ended despite fixing the turbo system leak (which I discussed in my previous post).
After being forced to stay back in Bangalore thanks to the problem, I set off next morning for Coimbatore. I found acceleration was smooth but I did not develop speeds beyond 120 kmph and found the engine gasping when I gave it full gas especially when I was overtaking another vehicle leading to a very dangerous situation.
I could do nothing about the problem immediately, being busy with work, but I checked into TVS in Trivandrum (where I went from Coimbatore) 3 days later.
Their diagnosis was that there was definitely fuel starvation most probably due to some blockage in the fuel tank and wanted to dismount it immediately - and take 2 days of course - to complete the work. This I refused being in midst of a tour and having to leave the next day. The second hypothesis they had was that the fuel pump was defective but I had to rebut that because the fuel pump has been leaking diesel for 2 years and I have not found any problems so far because of that.
Therefore, we settled for the flushing & decarbonising routine which is supposed to clean injectors, etc. This was the quickest solution that they could think of.
All fuel lines were checked - for cuts, blockages (by blowing compressed air into the pipes) but although the flushing/decarb routine did improve matters and the engine could rev up beyond 3500 rpm, yet it did not feel smooth.
The fuel feed pipe - feeding the fuel filter - was changed (I have already changed the rubber pipe from the filter to the fuel pump earlier). And that worked - the 6-year rubber pipe was indeed the culprit and I found the accelerator pedal lighter and the power back to its old form.
The most positive fallout: the leak in the fuel pump has COMPLETELY stopped! Thinking about that, it looks that the injectors were not consuming their full quota of fuel which was obviously creating back-pressure in the fuel pump and the ensuing leak. Last 2 days, I have driven 2,800 kms in the last 2 days & 2 nights non-stop and the engine never lost its rev, I got to top speeds of 150 kmph easily and the fuel pump has stopped leaking (something which used to happen earlier on my full-speed long-distance non-stop drives).
Lessons learnt:
- Replace rubber fuel pipes if >3 years old
- ASCs come up with predicatable responses by which they try to get rid of the problem in their courtyard - blaming it on fuel pumps (so that Bosch or Lucas have to do the work)or cleaning fuel tanks - Fuel system problems can be due to least-expected reasons. I have been badgered to open my the fuel pump - to cure it of its leak - but a cleaning of injectors and changing of feed pipes has stopped the leak!
Let me give you my analysis of the problem (I am no techie, so pardon my lack of understanding of vehicle mechanicals):
1. I used to do the flushing/ decarbonising routine regularly at the ASC till around a year ago. Never had a problem with power drops earlier, started in the last 1 year.
2. I have never cleaned the injectors so far.
3. I use mostly hi-speed diesel which is supposed to keep injectors happier.
4. When the power drop problem started, I had the air filter checked (because that causes less air intake and hence lower power), the fuel filters checked (because that restricts supply of fuel to the fuel pump), the leakage in the fuel pump (since my fuel pump has been bleeding diesel and hence could be pumping in less), topped up on fuel (since contaminated diesel could be causing problems) before getting onto more complicated issues like clogged injectors, loosened pipes for turbo system/fuel system and so on.
5. One obvious culprit was contamination/ particle blockades inside the fuel tank, especially in the "mesh" where the fuel gets out of the fuel tank. But that means dismounting the fuel tank, emptying it, pouring some cleaning fluids inside and then flushing it out after a few hours. I have never done this before in 6 years, mainly because it is a skilled job and ASCs are known for their poor workmanship. I have done this before in my earlier cars and lived several months thereafter of agony with fuel tank abrasing other components, and so on. During this long trip, I neither had the time nor the inclination to waste time or invite further problems, and hence I did not want to do this.
6. The turbo system problems were fixed - as explained in the earlier mail - and that ruled out any leaks there which could be causing turbo lag or poor functioning of the turbo itself.
7. The fuel pump has been leaking for last 2 years, and I have shown it to Bosch service centre, but we have consciously decided not to open it up - very expensive affair, calibration also gets affected - and since the leak must be due to a O Ring, we decided to leave it alone since I had no problems with acceleration of power.
8. Fuel feed lines and the injector were key suspect nows. Each fuel feed pipe was examined and flushed out with compressed air. There are 3 feed pipes - tank to front, intake for fuel filter and intake for fuel pump. While the first is partly metal, the rest are all reinforced flexible rubber pipes. And rubber has a lifetime of 3-4 years, and I think they SHOULD be replaced at least every 3 years regardless of kms run. I have replaced the fuel filter-fuel pump pipe before, but not the rest. Needless to say, a cut or ballooning of the rubber inside the pipe could be constricting supply of diesel to the pump and engine.
9. The injector clogging - I address it by using Hi-Speed diesels which are supposed to clean out the fuel systems including injectors. Many purists and the M&M ASCs themselves advise against using them, but I have been using them on and off all these years and my engine and fuel pump are none the worse off for that. In fact, from the moment I switched back to ordinary diesel, problems of power loss have started. I have never used System D which is also supposed to do the same cleansing work.
10. In my case, it looks to me that either the injectors were clogged or the fuel feed pipe was to fault - because everything has become OK when I flushed/decarbonised the fuel pipes and changed one of the fuel feed pipes.
11. Not only did the power come back, but also the fuel pump leakage stopped. I had a detailed discussion with a friend who is sound on pumps and he explained that back pressure created by poor spraying from the injectors could result in fuel trying to return to the fuel pump, creating pressure on the fuel pump body and exerting pressure on the seals (like O Rings), and over a period of time eroding them. Maybe that is why the O Ring in the fuel pump started bleeding diesel. This used to happen typically in high-speed runs when I am flooring the accelerator and fuel supply is at the highest. Therefore, when the injectors are unable to take in the fuel that the pump supplies it, there is shuddering and leakage of the "excess" fuel inside the fuel pump itself. Now that the injectors/fuel flow is restored to normal, the pressure against the fuel pump body have ceased and leakage itself gone. I have driven over 3,500 kms after the cleaning and the fuel pump body looks dry. Need to review it after a few days to ascertain if it is really gone.,
12. The overall conclusion is (a) clean injectors, and (b) change rubber pipes after 3 years.
BTW, in case you are wondering why my Scorpio is having so many problems, please remember that it has crossed 2.68 lakh kms in 6 years or so, and is definitely the rigours of old age are showing up.
Last edited by hvkumar : 22nd April 2011 at 23:18.
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