Possible fuel issue ? Help

Hey guys.
So ive had some troubles with my old girl over the past few weeks
Its a zd30 Di manual Nil dawes yet

So the issue I have is that it would just cut the engine out while driving, initially it would do it around 2500revs on and off and get worse until I turn the car off and leave it for 5 mintues then it would drive again without a problem.

I changed the fuel filter, it was full of gunk like the filter element had come loose, I was on my merry way for another week, again the same thing but worse, this time it wouldnt restart. Noticed my fuel lines to the filter are showing some signs of cracking at the top, so replace both of those and blocked the EGR while I was there and it's working fine for another day.

So this morning it starts no issues at all, drive my son to school then head to the shops, no issues, Drive again later in the day a short distance and once I try restart the car is wont kick over, It cranks no worries at all. It turned over after waiting 5-10minutes but had like a small missfire and ran rough for a short time before idling normally. Tried reving it and it would missfire at 2500, Didnt want to drive it as i was already late for work and the car was in a safe spot to stay while I went to work.

Any ideas on where to start to look ?
I did some searching, Possible air leak in the fuel line ?
I cleaned the MAF the other day and its all clean, new air filter, new fuel filter, nil leaks in my intercooler or cooler pipes.

I have no access to a scan gauge, am new to the area at Browns plains, QLD, So if any of the qld guys can recomend a good diesel mechanic in the area that wont rip me off that would be great

Thanks

Oh just to add its not overboosting, sits around 15-16psi, and EGT are always less then 350 usually less then 250 around town

Think you've found the problem yourself. I'd be removing fuel tank and cleaning it internally.
At the same time replace all fuel and vacuum lines, clean and change filters at the same time.
By doing this you'll eliminate fuel as part of your problem. Mates ex DX Telstra did what yours is doing.
vacuum hose is 20cents a mtr, IMO your picking up junk from inside the tank.
one less thing

Cheers td. Will try those things see if it helps.
It's such a pain that its so unpredictable and can't always reproduce it.
Drove home last night after work without any issues at all !

To me all things point to some crud in the tank,
cant hurt to clean it out as it will eliminate that as a cause

So it broke down again, got RACQ to look at it, by the time they got there it started again and ran until i drove down the road and it stopped. Towed to the mechanic who strait up said it was the injector pump until we had a chat and showed him it does start.

The problem being the lift pump/primer on top of the filter isnt holding pressure, it pumps up hard, start the car then it wont go hard again until you turn off the car and pump it up

I'm with threedogs on this.... it definately sounds like you are picking up sludge still. It's possible that, even though you have cleaned the filter etc, there is still more in the tank. It could possible be running rough due to clogged injectors. A cheap trick to try, before cleaning everything, is some F10 or similar to try to break down any possible sludge/water in the system. (F10 is a fuel additive from one of the motoring shops) I just used some on my truck after trying to drown it. Worked a treat as the other option was going to be expensive.

I believe (and stand to be corrected) that the manual fuel pump only stays firm until the truck is turned over the the pressure is released so I think that is normal.

So they had no luck with any leaks or blocks, they think it might possibly be faulty injector pump solenoid, they are waiting to hear back from some one else blah blah longer wait to get it seen/fixed

Another call back. They have got it down to a sensor fault, once the car gets to a certain temperature it shuts off then when it cools down it will run again, they are thinking possibly the crank angle sensor so fingers crossed !

Well its not the crank angle, also the top of the radiator perished. I am so over this. Its been in there all week and they have no idea whats wrong

I have the same problem as you, mine started about 6 months ago first just a hiccup not a complete stall every now and then. Now I cant even drive it down the street without it stalling. The mechanic I take it to as yet hasn't figured it out as when I take it back it seems to be running perfectly [ only stalled once for him ] The last time I left him I took it for a long drive about a 100 Ks no problem a couple of hours later went to take the dog for a walk problem back. Taking it back on Monday. Let me know how you go and visa versa.

By the way its a 03 3lt ST turbo. I am wondering if it could be the engine immobilizer switching in and out? will ask the mechanic on Monday.

Will keep you updated. They are looking into if it is the NATS causing it.
But exactly as you described works so intermittently will drive great. Get back and won't start. No misfire or rough running when it is going, Engine just cuts out dead.
Going to ask them which faults are showing up. Apparently there are a few showing up

Okay, after I spoke to you on Saturday a old friend [ex cocky ] phoned to say hallo. I mentioned that I was having a problems well to cut the story short he told me add an fuel additive called RISLONE DIESEL FUEL SYSTEM TREATMENT results as follow: Sat- no change Sun- still cutting out but could keep it going by giving it a few squirts of juice today-ran like a trooper of and on did about 150Ks hammering it on all types of roads even took it down the beach, let the motor cool down and started again, 2 slight hiccups in the first 50Ks and I swear it ran better than it's ever done. Anyway I am going to drive it as normal for the next week and keep my fingers crossed. Ill keep you posted.

Back in the workshop.

Thats no good stumpie!

Just got the final verdict on mine. The injector pump is the culprit so its getting rebuilt over the next few days

thanks for the info. How much is that going to cost?

$2500 for the rebuild $1500 labor. 12hr job to pull out and put back in ive been told.

I don't know if you want to hear this but I mentioned that my problem might be the pump to my mech. [ answer no way in the world ] His idea after re- checking everything he sent me to a sparky who took the ecu relay out cleaned the female plug put a new relay in charged $50 [relay $36.20 ] No problems 2 days now. I'm keeping my fingers crossed. By the way my heater for the engine works 100% never did before used to work every now and then. Please let me know how you go, thanks.

I tried all that aswell replaced with different relays. Ended up with a cam sensor fault?

Howd you go stumpie ?
$4660 later mine is all going again

So far no problems, have been using it every day . Touch wood. Cant afford that type of money.

Thought give an update. Still running like a trooper,the only variance I can see is when I start her in the mornings is the revs starts at 750 app then drops to 650 then back to 700 all within about 10 seconds then stays at 700 no matter what. Any advice would be a great help.