D4D Engine Cuts Out

[paris the yaris]

I have read a few other posts from people suffering the similar problems but I as yet havent found the solution any ideas??

The background is familiar, under hard acceleration or perhaps a long uphill run on the motorway, the engine dies, the engine management light comes on and we have to find pull over, manually pump the diagphram lift pump on the fuel filter housing, and after a few turns of the key, away we go again and the light gos out.

Diagnostics show the fault as being Fuel pressure code, to date I have done the following:-

New fuel filter

Checked the tank pick up tube

New fuel metering valve on the common rail pump

New suction valve within the common rail pump

New suction side (gear pump) of the common rail pump

Testing of Common rail pump by Bosch specialists

An Injector leak off test (the injectors were rufurbished about 25k miles ago)

All the indicators are that it is a fault on the supply to the pump, my next action is to investigate the fuel filter housing, and check all the flexible hoses and supply pipework for restrictions or internal damage.

The vehicle has done 75k miles, the first time I encountered this problem was about 2 years ago, however the rate of failure is getting worse.

[BJames]

First thing I did was have egr valve cleaned, have u done this?

[paris the yaris]

Yes, I cleaned the EGR, but have since blanked it off by making a stainless steel plate to replace the gasket, as I was advised by the Toyota mechanic who help me with the diagnostic code.

[igormus]

New fuel filter ----> have you bleeded fuel system well ?

Checked the tank pick up tube-----> what did you find?

New fuel metering valve on the common rail pump

New suction valve within the common rail pump----> have you changed both SCV---reason ? ?

New suction side (gear pump) of the common rail pump----> it looks you ve dismantled HP fuel injection pump?

Testing of Common rail pump by Bosch specialists ----> what max delivery pressure have they recorded ?

An Injector leak off test (the injectors were rufurbished about 25k miles ago)---> all injectors must to have the same circle diesel dlelivery

[paris the yaris]

Thanks for your posts.

I have changed and bled the fuel filter a number of times since owning the car.

The tank pick-up strainer was clean.

I changed the metering valve and SCV within the pump as they could have displayed the same symptom, if faulty.

The suction side was changed by the Bosch specialist.

I do not have as yet a record of the maximum delivery pressure, however I was told verbally that it was OK, but the test rig for these Bosch CP3 type pumps has a pressure fed supply (0.3bar) and therefore the suction side is not measured or tested.

I can feel a small amount of suction from the pump when removing the supply pipe to the fuel filter.

I will investigate the pipework for restrictions soon, I will also look a the fuel tank breather, may fit some temporary pipework to eliminate various parts.

[igormus]

it is clear the air is stil in the system or some rubber hoses might be cracked on the upper side preventing leak

by the way -- do you have boosting pump in the tank as generated into filter/level sensor ??

[igormus]

do not forget to check with rail pressure sensor + its contact

as to SCV -- botho coils resistance must be valued depending on surrounding temperature

[Devon Aygo]

What is the DTC fault code that accompanies this issue? Also could you PM me your registration # or chassis #

Cheers

Devon

[paris the yaris]

I have had feedback on the common rail pump test.

The pressures were:-

Tickover 330bar

Maximum rpm 1400bar - ( 50 bar above the specification)

There is no pump in the fuel tank, therefore the suction side of the common rail pump has to create lift from the tank.

I have as yet to fit new hoses etc.

Any other ideas gratefully recieved.

[igormus]

the unit in the tank consists of (level sensor + pump + filter)

what about SCV ??? have you tested them ?

it looks the engine is short of fuel or an air is still in the system or fuel pump sucks an air thru fuel lines

[jonquirk]

Based on similar symptoms experienced with a VW LT35D some years ago I would be inclined to suspect that one or more flexible hoses in the supply from the tank to the injection pump is porous causing air to be sucked into the system. This problem never gets better, only worse, and can become so bad that the engine fails to run long enough to recharge the Battery power used cranking the engine to get it started. You are then stranded! It may be instructive to substitute each piece of pipe with a known good piece in turn to find the culprit and to determine that it is the pipe that is actually causing the fault.

I arrived at this test only after I had replaced my fuel filter, water separator and removed the fuel tank for inspection and not cured the fault!

[Geoff Peace]

I have had feedback on the common rail pump test.

The pressures were:-

Tickover 330bar

Maximum rpm 1400bar - ( 50 bar above the specification)

There is no pump in the fuel tank, therefore the suction side of the common rail pump has to create lift from the tank.

I have as yet to fit new hoses etc.

Any other ideas gratefully recieved.

I do not know about the Yaris, but a fault I have encountered more then once on other makes is the fuel filter mounting becoming perforated and admitting air. Secondly the casting can deteriorate over time and admit air between the casting and the inlet/outlet pipes. Just a thought!

Regards Geoff Peace.