Problem with fuel system

Hi Guys, got problem with fuel system on my 300 tdi, wife ran tank VERY low last week & she is now running lumpy, coughing & farting etc etc, the disco that is not the wife. So cleaned the sedimenter as advised (thanks Biglad). The amount of crap that was in there was unreal!! wonder she ran at all. Had to take sedimenter off completely as the bolt would not budge,all back together, removed drain plug & no fuel, refitted & turned over on the key, she fired up, cut the engine loosened drain plug & clean fuel dripping out so thought all ok there. Started up but still running lumpy, so loosened bleed screw on fuel filter & FUEL EVERYWHERE!!
So guess that was ok, but still running lumpy! Then cracked injector pipes 1 by1, engine still running fuel spraying out & started to run smoother so thought all ok. Left it running for a while, seemed ok hit throtle a few times seemed ok so went on test drive, fine to start with then started coughing & farting quite bad but still running. should i change fuel filter or bleed system again or both? Also did egr blank & this is first time running since would this make any difference? Any thoughts appreciated.

Change fuel filter and try it before you get worried

Have you filled up since this issue ?

Do as the above with the fuel filter but I do believe you can get some thing from Halfords, to wack in the fuel tank to clear that will sort out doggy running

Thanks guys, yes i have filled up, now thinking this could have disturbed any crap in tank as i used lorry pump. But will change filter & see what happens, thank again

If the sedimenter was choka with crap,the filter is the next in line,so change that first,only a couple of quid

Hi guys, changed filter & bled, went for test drive all fine untill temp reached normal then started coughing, so pulled over reved engine still coughing & cloud of black smoke, reved again up to 4000rpm a few times seemed to run better & no more black smoke, so off i went again dual carridgeway this time driving hard upto 80mph& only started coughing at 3750-4000rpm after that it was fine. Being an auto you have to drive really hard to get revs upto 3750rpm so i assume normal driving should be ok. will this coughing clear in time? thanks for all advice recived.

Discodave2011 said:

Hi guys, changed filter & bled, went for test drive all fine untill temp reached normal then started coughing, so pulled over reved engine still coughing & cloud of black smoke, reved again up to 4000rpm a few times seemed to run better & no more black smoke, so off i went again dual carridgeway this time driving hard upto 80mph& only started coughing at 3750-4000rpm after that it was fine. Being an auto you have to drive really hard to get revs upto 3750rpm so i assume normal driving should be ok. will this coughing clear in time? thanks for all advice recived.

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have you checked/cleaned the fuel sedimenter?

If the sedimenter is clear it may be worth checking your air filter and that your turbo hoses aren't delaminating and the symptoms are just a coincidence.

Thanks for reply Ratty, sedimenter cleaned, fuel filter changed, air filter looks new, just fitted egr blank & new hose to intercooler. how do you check for hose delamination, as i am new to throwing the spanners around a disco not quite sure what to look for.

Discodave2011 said:

Thanks for reply Ratty, sedimenter cleaned, fuel filter changed, air filter looks new, just fitted egr blank & new hose to intercooler. how do you check for hose delamination, as i am new to throwing the spanners around a disco not quite sure what to look for.

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pull the turbo hoses off and check that the insides haven't started seperating and creating pockets/flaps that obstruct the air flow when the turbo spools up.

Thanks for that Ratty, will take a look at weekend.

Hi guys, thinking of taking BIG hammer to it now,its really bugging me now.:doh:
Recap on jobs so far: cleaned sedimenter, had to remove completely to do this as could not budge 11mm bolt also had to cut fuel line on pump side,
heat fuel pipe & push onto union ( noticed all joints are like this, with no clips ) bleed system still running the same! Change fuel filter & bleed, still kin same! Towed caravan 160 miles coughing & farting but not too bad, once wound up would tow at 70mph no problem, just a pain when away at junctions but not allways doesnt seem to be a set pattern. Driving around while away still same but drivable untill day before due to come home it got really bad, blead injector pipes & it was fine! for 5 miles or so then the odd cough. Towed home much same as going down, have blead injectors couple times since & is ok for a time.
Changed lift pump yesterday blead & you guessed it STILL F**KIN same!! checked fuel lines wot i could see looked ok no sign of any problems.
Checked sender unit connections, looked a bit cruddy but solid when scraped with screwdriver. Where return pipe enters sender plastic is cracked but no sign of any leaks. HELP SOMBODY !!

was it bleeding ok? once you have run it are you getting air back in the system? sounds like a pin hole in the fuel line somewhere to me!

Hi Lyndon, i was thinking along the same lines, the only thing i cant understand is it was running fine when i first got it in early Jan, er in doors run tank VERY low & has had this problem ever since. Seems to be around 1500-2000rpm & 3500-4000rpm but not all the time & seems worse when cold. Have also put Wynns injector cleaner in fuel. Fuel pipe is plastic & push fit on to union fittings with no clips anywhere.

fit clear plastic pipe to front injection pump feed and check for air pipe can be left in place ,if air replace pipes from tank to lift pump to be sure of curing fault ,the steel pipes rot

Hi guys, PROBLEM SOLVED!!! the joint i had to remake after cleaning sedimenter weeks ago was sucking in air, although not leaking any fuel.
So guys if you need to make a joint with plastic fuel pipe add a hose clip as well, this will save you no end of head scratching, swearing & cursing.
Landy now running fine, can now get full use of egr blank & de-cat pipe!