KZN130 3.0ltr Diesel stalls and CEL comes on

[legocar]

Hi,
We have an intermittent problem with our new Surf. It drives well and runs fine most of the time but every now and then the engine stalls without warning (which is no fun in an automatic I can assure you )

It happens once she's fully warmed up, and so far its only happened when we are slowing down to stop or crawl. The engine cuts out, the Check Engine Light comes on and she won't start back up again for 10 seconds or so. Then she fires and runs perfectly

I've ordered a new set of filters from Milner as they are well overdue for replacement and I'll give the vacuum hoses a once over today, but is there anything else I should be looking at? Or more to the point at the moment, is there anything else that's relatively cheap that I should be ordering at the same time?

I don't want to pop the bonnet next weekend and discover that the fault lies with a 50p grommet that's gonna take a week to arrive by mail. I'd rather order it now and replace it just in case......

Any hints or advice would be gratefully received, especially from anyone out there who has had similar problems.......

[andycook]

first step would be to find out the engine fault code - do a search to find out how to do that.
the engine code may help then to track down the problem

[legocar]

OK so I replaced the Fuel, Oil and Air Filters, run a dose of Redex through the Injectors, checked all the vac hoses I could find and generally gave everything under the bonnet a once over (checked for disconnected harnesses, damaged wiring etc.)

Everything went fine and she's now running like a new car...... but still cuts out!!!!!

I checked for fault codes following the instructions on another thread, but all I get is the "O/D Off" message and "Check Engine" Light flashing constantly (no code just repeated flashing).

Any suggestions.....?

I said at the start of the thread that the CEL comes on, but I suspect that this isn't actually true. I think it just comes on with all the other lights when the engine cuts out (like every light comes on when you switch the ignition on)

[legocar]

I still need help.......

...... and the latest development is.....

My wife was driving it to work this morning and it cut-out again, but this time wouldn't start again for 10 minutes or so and when it did start, it cut out again after 30 seconds without actually driving anywhere.

The very nice man from the RAC was called and he had a quick look at it and reckons its probably the fuel pump.... he says there are two on the vehicle, one on the engine that pushes the fuel thru the injectors and one on the fuel tank that supplies the fuel to the engine bay.......? He says that the one on the tank is failing to supply enough fuel.......? Does anyone know if he's right about the two pumps?
His theory doesn't really stack up with the failure mode, but what would I know?
When the wife asked if it would be expensive to fix, he walked round the back of the car, looked at the number plate then did that sharp intake of breath thing whilst nodding wisely...... why do they do that? and why did he look at the plate? is he just assuming that because its an import it will cost more to fix?

The car is now sitting in our local Nationwide Autocentre waiting for the "experts" to decide how much of my money they want to steal, but if anyone out there has any clues whatsoever, I'd gladly hear them......

[sledge]

there are 2 fuel pumps on the surf one is a primer and one is the main pump. the primer is the one locate in the engine pay under the fuel filter which you do by hand the other is (looking at truck) on the righthand side at the botoom of the engine. there is no fuel pump on the tank it's self. but there is a filter on the fuel tank do you get a hiss when you open the filer cap? you sshould be able to get a 2nd hand fuel pump for around £200-£300. if thats what it is. to me it just sound like fuel starvation. has the truck had any work done on it recently.

just an after thought what condition is your air filter hose in. if it's to badly knackered it could cause your problems.

[legocar]

Thanks for the response Wolf.

No work done recently to my knowledge and the Airfilter hose is in pristine condition (like most of the rest of the engine bay)......
Wouldn't fuel starvation be more apparent under load than when idling?

Do you know how big a job changing the fuel pump is on a Surf? I had a nightmare once with a reconditioned pump on a Toyota Lucida that ended up costing me over £1500 ...... an experience I'd rather not repeat.

I think I've seen a few people on here mention the "fuel cut-off solenoid" and "Idle control valve". Is it possible that one of these could be the cause of the problem?

[sledge]

personally i've never changed one, but from readin what others have put i dont think it's to tougher job to do. only thing is you have to get the pump timing right.

not sure about the rest your best bet would be to ask tonyN, bushwacker, surfenstein or sumone whos had to fit one.

i'm sure theres some threads on here about it.

[ben2611]

Just checking - you hadn`t just filled the tank up had you? Its an obvious one I know but fuel contamination can generate this. I don`t just mean putting unleaded in either. My mate filled up at a BP the other day and his diesel car broke down three times within three hours!

[legocar]

Just checking - you hadn`t just filled the tank up had you? Its an obvious one I know but fuel contamination can generate this. I don`t just mean putting unleaded in either. My mate filled up at a BP the other day and his diesel car broke down three times within three hours!

No, its been stalling for a few weeks and has had several top ups from different petrol stations since it started to happen.

The thing that doesn't stack up for me is that in every other respect, the engine is running sweet as a nut. I would have expected something like fuel contam or a faulty fuel pump to have a more frequent and severe effect on the way it runs.

Thanks for your input tho......

[charvell]

is it overfueling? woud that cause it to do this?

[legocar]

is it overfueling? woud that cause it to do this?

That would make a bit more sense, given that it stalls during decelerration, although I'd expect a bit more smoke if it was over-fuelling.

I was hoping that there would be some members out there who had experienced the same problem........?

[legocar]

Nationwide reckon it may be the Crank Sensor?????

Not entirely sure why they think this, but they've ordered a new one from Toyota and tell me they won't charge me for it if it doesn't cure the problem....... and pigs might fly .

Only problem is, its gonna take three days to get here.....

[NiftyNev]

There's a small filter under the Fuel Temperature Sensor that can get blocked. The sensor is on the outside of pump toward the back.

Nev

[ben2611]

Does it cut out suddenly or does it cough and splutter and die? If it stops instantly it may be the crank sensor as this will send the info to the ecu, but it may be another electrical issue. Spluttering to a halt will point more to a mechanical fueling issue - filters, pump, blockage etc.

If Nationwide don`t charge you for at least something I will be impressed!

[legocar]

It is fairly abrupt, i.e. one minute there's power, the next there's none. The car doesn't shudder or lurch, it just stops.

Oh and I'm certain Nationwide will charge me....... just not for the cost of the sensor