300Tdi fuel feed issues

chris snell

chris snell

Administrator
Callsign: NW5W
Staff member
Drove my truck yesterday for the first time in a few months and it seemed to run fine. Today, it wouldn't start. I drained some funk off the bottom of the sedimenter (not much...maybe half a teaspoon) and drained a little clean fuel from the bottom of the fuel filter but it still wouldn't start.

Opened the bleed screw on top of the fuel filter and cranked the starter (with IP fuel solenoid unplugged) but that didn't result in any fuel sputtering through the bleed hole. I pressed the lift pump for a while and eventually fuel sputtered out the bleed hole so I started the truck and it ran for a minute then died.

Tried manual lift pump again but it wouldn't raise the fuel level in the filter like it did the first time.

Finally, I had a friend start the truck and give it gas while I checked for problems and then I noticed that fuel was sputtering out the top of the fuel filter where it meets the housing.

Presumably, the o-ring dry-rotted from not being driven enough.

So, a few questions:

- Is there a compatible fuel filter that I can source locally?

- Does the filter include the o-ring or is that separate?

Robert Davis, if you're reading this, can you post some links to the parts that I need for a 12V inline pump? I'm going to finally follow your advice here...
 
chris snell

chris snell

Administrator
Callsign: NW5W
Staff member
Update: removed and checked the fuel filter seal and it looked good. Reinstalled and snugged down and it's not obviously leaking anymore. Started the truck and it ran for a minute and then died.

Still not sputtering fuel from the bleed hole on the filter.

Bad lift pump?

Clogged tank pick-up? (ughhh.. hope not this)
 
jymmiejamz

jymmiejamz

Founding Member
Callsign: KN4JHI
chris snell said:
Bad lift pump?
Click to expand...

I'm no diesel expert, my experience has been the truck will run fine with a bad lift pump. My 300 Tdi had problems starting but would eventually start after enough cranking. After a few months I finally replaced the lift pump and all was well. I would think once the truck is running the injection pump would do the job.
 
RDavisinVA

RDavisinVA

Technical Excellence Contributor
chris snell said:
So, a few questions:

- Is there a compatible fuel filter that I can source locally?

- Does the filter include the o-ring or is that separate?
Click to expand...

Here's the list, all have the o-ring for the filter element:
Most common of all spin-on filter elements used worldwide.
List of manufacturer part numbers for this filter element:
ALFA ROMEO 71736113
ALFA ROMEO 71736116
ALFA ROMEO 71736119
ALFA ROMEO 46773577
ALFA ROMEO 9950443
ALFA ROMEO 60507208
ALFA ROMEO 116760469602
ALFA ROMEO 116760469601
ALFA ROMEO 116760469600
AUDI - VW 068 127 177 B
AUDI - VW 068 127 177
FIAT 60732867
FIAT 994 4921
FIAT 74434895
FIAT 9936891
FIAT 82406319
FIAT 79075882
FIAT 74035556
FIAT 5981936
FIAT 5962400
FIAT 5951661
FIAT 4814454
FIAT 4813127
FIAT 4795601
FIAT 4764725
FIAT 1930010
FIAT 1902138
MAHLE KC 38
MAHLE KC 18
MAHLE KC 32
MAHLE KC 43
MAHLE KC 68
MAPCO 63110
MEYLE 100 127 0005
PUROLATOR F 57729
PUROLATOR F 57805
PUROLATOR F 60217
PUROLATOR F 68000
PUROLATOR PER 248 F
PUROLATOR PER 152 FO
PUROLATOR PER 152 F
PUROLATOR PER 152
PUROLATOR F 78367
PUROLATOR F60152
PUROLATOR F 67803
PUROLATOR F 57721
PUROLATOR F 57248
Napa 3472, Wix 33472, 33472MP
Fram: P1145A, P3522, P3522A, P4587, P7510, P7512, P7701, P8043, PS8428, PS8787
Volvo: 860874-7, 1141572-6
Baldwin: BF1226, BF7921
Carquest 86472
FORD - MOTORCRAFT - FOMOCO 1145 7434058
FORD - MOTORCRAFT - FOMOCO 1145 7434105
FORD - MOTORCRAFT - FOMOCO 0450 133003
FORD - MOTORCRAFT - FOMOCO 8784 0509
FORD - MOTORCRAFT - FOMOCO EFG 048
FORD - MOTORCRAFT - FOMOCO EFG 057
FORD - MOTORCRAFT - FOMOCO T81D C9150 BA
FORD - MOTORCRAFT - FOMOCO 6135 130
FORD - MOTORCRAFT - FOMOCO 5020 403
FORD - MOTORCRAFT - FOMOCO FD-784-A
FORD - MOTORCRAFT - FOMOCO EFG 035
FORD - MOTORCRAFT - FOMOCO F 0 NN 9176 BA
FORD - MOTORCRAFT - FOMOCO 5010 462
FORD - MOTORCRAFT - FOMOCO 5012 582
FREIGHTLINER ABP/N10G-FS1251
GM - GENERAL MOTORS 93156288
OSCH 1 457 434 173
BOSCH 1 457 434 107
BOSCH 1 457 434 094
BOSCH 1 457 434 099
BOSCH 1 457 434 101
BOSCH 1 457 434 106-30N
BOSCH 1 457 434 110
BOSCH 1 457 434 113
BOSCH 1 457 434 119
BOSCH 1 457 434 121
BOSCH 1 457 434 150
BOSCH 1 457 434 151
BOSCH 1 457 434 156
BOSCH 1 457 434 174
BOSCH 1 457 434 106
BOSCH 1 457 434 166
CHAMP FS 50
CHAMP FP 587 F
CHAMP FS 122
CHAMPION L 112
CHAMPION L 111
CHAMPION L 113
CROSLAND 5006
DELPHI FF0056
DELPHI FF0105
DELPHI FF0054
DELPHI - AC DELCO XD 77
DELPHI - AC DELCO XD 9043 E
DELPHI - AC DELCO TP 1069
DELPHI - AC DELCO XD 67
FEBI - BILSTEIN 17660
FLEETGUARD - CUMMINS FF 42006
FLEETGUARD - CUMMINS FF-5060
FLEETGUARD - CUMMINS FS-1276
FLEETGUARD - CUMMINS FF-5135
FLEETGUARD - CUMMINS FF 5135
FRAM P-5498
FRAM P-5905
FRAM P-4183
FRAM P-8043
HENGST H 70 WK 02
KNECHT AWK 126
KNECHT AWK 126/1
KNECHT FB 650
LUCAS HDF 496
LUCAS 496
LUCAS 7176/496
LUCAS 7176/496 A
LUCAS 7111/496
LUCAS 7176/496
LUCAS 7176/496 A
LUCAS HDF 496
M FILTER MP 462
MAHLE KC 18
MAHLE KC 32
MAHLE KC 38
MAHLE KC 43
MAHLE KC 68
MANITOU 109 985
MAPCO 63110
MASSEY-FERGUSON 3 638 291 M
MASSEY-FERGUSON 3 638 291 M 1
MECALAC E537A0016
MEYLE 100 127 0005
MONARK DIESEL 30 789 106
MOTAQUIP AAPCO VFF 105
MOTAQUIP AAPCO VFF 278
MOTORCRAFT EFG 035
MOTORCRAFT EFG 048
MOTORCRAFT EFG 057
NEW HOLLAND 1930010
NEW HOLLAND 8780 0220
OPEL 813 565
OPEL 90 016 800
PBR BG-1534
PBR BG-1569
PBR BG-1584
PERKINS 26 560 608
PERKINS 26 561 118
PERMATIC MECAFILTER ELG 5204
PERMATIC MECAFILTER GF 282
PEUGEOT 1906-60
PURFLUX CS 183
PURFLUX CS 197
PURFLUX CS 197 A
PURFLUX CS 197 B
PURFLUX CS 412
PURFLUX CS 412 B
PURFLUX CS 454
PURFLUX CS 469
PURFLUX CS498
PURFLUX CS 701
PUROLATOR F 57248
PUROLATOR F 57721
PUROLATOR F 57729
PUROLATOR F 57805
PUROLATOR F60152
PUROLATOR F 67803
PUROLATOR F 68000
PUROLATOR F 78367
PUROLATOR PER 152
PUROLATOR PER 152 F
PUROLATOR PER 152 FO
PUROLATOR PER 248 F
RENAULT 7 700 668 711
RENAULT 7 700 700 092
RENAULT 7 701 030 195
RENAULT 7 701 030 546
RENAULT 7 701 668 711
RENAULT TRUCKS 5 001 846 099
RENAULT TRUCKS 5 001 850 947
RENAULT TRUCKS 7 700 700 092
RENAULT TRUCKS 7 701 030 546
ROVER AEK 2147 L
ROVER AEU 2147 L
RYCO Z118
SAVARA 9.28.327.17
SAVARA SN 327
SAVARA SN 468
SAVARA SN 563
SAVARA SN 602
SCHAEFF 5.411.656.301
SCHAEFF 5.568.656.484
SCHUPP - SF FILTER SK 3820
SEAT 000 446 5121
SOFIMA S 8500 NR
SOPARIS CVN 9249
SOPARIS CVN 9266
STILL 0 141 762
STILL 1 141 762
STILL 141 762
TECALEMIT FF 5332
TECNECO GS 110
TECNECO GS 57
TECNECO GS 58
TECNOCAR RN 110
TECNOCAR RN 110 B
TECNOCAR RN 231
TECNOCAR RN 234
TECNOCAR RN 57 B
TECNOCAR RN 58 B
TEHO FILTER 6206
TJ FILTERS FF 5332
UFI 24 351 00
UFI 24 355 01
UNICO FI 8155/2
UNICO FI 8159/2
UNIPART GFE 5297
UNIPART GFE 5304
VOLVO 1257201
VOLVO 1257201-2
VOLVO 3976655
VOLVO 39766555
VOLVO 3976655-5
VOLVO 829993
VOLVO 829993-5
VOLVO 829 993-5
VW - AUDI 068 127 177
VW - AUDI 068 127 177 B
WIX 33472
WIX WF8042
WIX WF8181
WYTWORNIA FILTROW PDS-71
YALE 580004421
YUIL FILTERS YFF-008
YUIL FILTERS YFG-012
 
V

Viton

Well-known member
One way or another, air is getting into the fuel system and is allowing the fuel to gravity feed back to the tank when you shut the engine off. The aux pump will probably alleviate the problem and allow you to see where the air is coming from by causing a fuel leak at that point.
 
chris snell

chris snell

Administrator
Callsign: NW5W
Staff member
At this point, I'm suspecting a failed lift pump. Truck idles, just won't run long with throttle. I ordered a new lift pump and will install and see if that improves things. I ordered the 12V pump that RD suggested and will get that plumbed up.
 
javelinadave

javelinadave

Administrator
Staff member
Any idea what the amperage for that pump is. It looks looks like it would be low enough that the relay wouldn't be needed.
 
chris snell

chris snell

Administrator
Callsign: NW5W
Staff member
javelinadave said:
Any idea what the amperage for that pump is. It looks looks like it would be low enough that the relay wouldn't be needed.
Click to expand...

Well, I'd hate to power it off the ignition switch and risk burning that out.

I will most likely do what I did on my previous truck: install a second Blue Sea fuse panel and power that with a big, fat relay switched by the ignition. I'll power the fuel pump off of the fuse panel. I have a few other accessories that I want to run as ignition-switched so that will be useful.
 
AdamSanta85

AdamSanta85

Well-known member
javelinadave said:
Any idea what the amperage for that pump is. It looks looks like it would be low enough that the relay wouldn't be needed.
Click to expand...

I couldn't find any published documentation and didn't want to take any chances. I just mounted the relay kit in the battery box and ran the power wire to the pump on the RH frame rail. I grounded the pump on the main ground on the upper RH side of the bulkhead by the heater box.

I used the Airtex E8153 as it is listed their diesel specific pump.

https://www.summitracing.com/parts/atx-e8153

Kc6hwxC.jpg
 
V

Viton

Well-known member
chris snell said:
At this point, I'm suspecting a failed lift pump. Truck idles, just won't run long with throttle. I ordered a new lift pump and will install and see if that improves things. I ordered the 12V pump that RD suggested and will get that plumbed up.
Click to expand...

So if the lift pump fails, can fuel leak into the oil pan ?
 
V

Viton

Well-known member
AdamSanta85 said:
I couldn't find any published documentation and didn't want to take any chances. I just mounted the relay kit in the battery box and ran the power wire to the pump on the RH frame rail. I grounded the pump on the main ground on the upper RH side of the bulkhead by the heater box.

I used the Airtex E8153 as it is listed their diesel specific pump.

https://www.summitracing.com/parts/atx-e8153

Kc6hwxC.jpg
Click to expand...

To me, this seems like a very bad location for these separators, under the vehicle at any location.
An errant rock could hit this thing, and even though made of plastic, and bust it causing one heck of a problem, even just busting off the drain-plug.
 
AdamSanta85

AdamSanta85

Well-known member
Viton said:
To me, this seems like a very bad location for these separators, under the vehicle at any location.
Click to expand...

I agree it is less then ideal, however there was no where else for it to go that made any sense without looking like a complete hack in the engine bay and making a mess of the fuel lines. The entire firewall and inner fender area is already occupied with stuff. The pump has to go after the sedimenter. I attempted to install it and stopped many times because I couldn't find a mounting location that really made me happy.

After spending $500 getting my injectors rebuilt due to them being clogged I decided it was time to mount it. Now seeing the gunk the sedimenter collects, to me, it is a worthy trade off. AFAIK the OEM sedimenters were located under the truck.

Aside from an errant object kicking up, my fuel tank, transmission cross member, and frame would take an impact before the sedimenter. I keep a 12" piece of fuel line in my tool kit. In the event something bad happened to it, I could bypass it in about 3 minutes with a flat head screw driver. I guess I could make a little shield for it?

Where is your sedimenter mounted?
 
rovercolorado

rovercolorado

Well-known member
Viton said:
To me, this seems like a very bad location for these separators, under the vehicle at any location.
An errant rock could hit this thing, and even though made of plastic, and bust it causing one heck of a problem, even just busting off the drain-plug.
Click to expand...
That's a good point. I got recommendations from several sources that this would be the good location. I think that it's close to the tank and has lots of room to mount and easy access to fuel lines that can be modified without much issue.
Maybe make a rock shield or find a location in the engine bay / bulkhead instead. I haven't installed mine yet so now I'm going to have to give it more thought.
 
V

Viton

Well-known member
chris snell said:
Not sure what you mean. If the lift pump fails, the injection pump is just left with what's in the lines already.
Click to expand...

There must be a rubber diaphragm in the pump & when/if that fails, and since the pump is driven by a lobe on the cam (hence a hole in the block) could fuel leak into the oil/pan from this point? I've never had this pump fail or do I know the internals of it, this is why I ask, just curious.
 
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