KZN130 3.0ltr Diesel stalls and CEL comes on

[Apache]

Have you checked the primer on the fuel filter housing? Check it goes hard (ooer) when you press it a few times. If not, it can produce symptons such as yours.

Its a cheaper and easier place to start than the other options!

[legocar]

The primer pump definitely seemed to be working ok.
When I changed the fuel filter it only took a couple of plunges of the button to fill the system back up and she started 1st time.

[legocar]

Ok so we get the car back from Nationwide tomorrow....

As I pretty much expected, they haven't been able to fix the problem...

What has come as a shock tho is that they're not going to charge us...... anything...... at all!!!!

I'm gobsmacked. They've had it 3 days, done loads (ish) of tests on it, swapped over the crank sensor and taken it out on at least 3 test drives...... I was sure they'd at least charge us £50 diagnostics fee.

At least I feel a bit better about not being able to diagnose the problem myself. If they're prepared to waive their normal charges cos they can't find the problem, it must be a tricky one......

However, I still have a big problem..... the car still has a fault and by all accounts, its getting worse.

I have a theory or two, but need some help from the technical gurus out there......

Firstly, the Idle Control Valve...... does it exist? Where would I find it? How does it work? and How would I test it?
Secondly, is there a vacuum hose diagram available for the KZN130 3ltr engine?
And finally, are there any other valves, switches, sensors, gizmos or gadgets that have any kind of effect on Fuel or Air supply to the engine, and if so, what and where are they?

I know the above is a big question..... several big questions in fact, but any help anyone can provide would be greatly appreciated and will hopefully help to ensure that we don't have to get rid of the surf.....

[swampy]

Do these have a fuel pump relay?
I once had a very similar problem on my Ovlov, changed the relay and away she went! It's a wild one but when your clutching at the proverbial.
Hope you get a fix.

[cazyp]

I had the same problem on a VW golf years ago.
There didn't seem to be an answer.
I replaced every filter/relay/vac pipe etc.

Until I found the leaf in the fuel tank which was getting sucked up to the outlet at random intervals making the car stall. Once stalled the leaf would fall away and the car would start again...

Not saying you have a leaf in there BUT the fault sounds identical..Maybe other 'crud.'

[legocar]

Right, hate to harp on about this but it's getting ridiculous now.....

We finally decided today that enough was enough and we'd have to just trade the surf in against somethin that worked. We picked a nice Vectra and I drove the Surf over to the dealer for him to value it...... at least that was the plan...... it broke down twice within the first mile of the journey so I decided that the chances of palming the surf off without him noticing were slim to none ...... and I was feeling uncharacteristically guilty about it anyway

The stalling problem is definitely getting worse and now it doesn't restart straight away either. Once it stops, if you try to start it again, it just turns over without firing. Five or ten minutes later it fires up sweet as a nut and runs fine.... until the next time it stalls

It's like someone flicked a switch.... now you have power, now you don't, now you have it again..... black and white, no grey areas..... does anyone else agree that it sounds like an electrical fault?

I know my way around a basic engine and I'd like to think I'm technically minded enough to work out how things do what they do, but my problem is that I'm not familiar enough with the individual components on this bugger, so I don't know what I'm looking at half the time...... any help would be appreciated.....

My wife has bought herself an old banger so that we can take the surf off the road til its fixed..... but we have to fix it!!! I have a 58 year old Landrover that's been sitting on the drive for the last 10 years.... I won't be allowed another "garden ornament"

[sledge]

your best bet is to fond away to get to one of the gurus on here and let them take a look at it.

[Diezel Weazel]

Have ya released the fuel tank cap ? n does it sounds it's pressurised ?
Check the small filter underneath (on top of/or alongside the fuel tank)
Check here ..
http://www.hiluxsurf.co.uk/forums/sh...ight=Fuel+shut
Hope this helps n Good Luck

"Cos short cuts cost more in the long term"

[BUSHWHACKER]

Sounds to me like you've got air in the fuel thats circulating around, as you didn't mention loosening off the injectors to get the fuel flowing after the filter change.

Or, there's crud getting sucked against the gauze filter now and then on the end of the pick up tube in the fuel tank.

[NiftyNev]

Did you check the filter under the Fuel Temp Sensor?

Nev

[s car go]

What about the fuel shut off soliniod?
This would defo stop the engine as if you were turning the engine off!
Regards
Mark

[surfenstein]

it could be a number of many things,and most of them have been mentioned already,the fact that you are not getting any fault codes up means that it wont be a sensor problem.(make sure you are reading the codes for a 3.0l and not a 2.4l they are different.)do you have an immobiliser fitted? have you checked the small gauze filter under the fuel temp sender on the back of the pump like nev asked.??? have you drained the tank(small bung under the tank) to see if the fuel is contaminated with anything thats in the tank.check your fuel lines too and from the engine,make sure the flexible fuel hoses have no cracks or cuts in them,it only takes a small amount of air in the fuel.look around the fuel primer head ,make sure all hoses and clips are tight,check the hoses themselves for cracks,etc.,make sure the throttle position switch is tight and does not move on the inlet manifold.leave the fuel filler cap off and take it for a drive.check the wiring harness in and around the fuel pump,make sure connections are clean and dry.the only other thing i can suggest is that you ask someone thats near you with another 3.0l surf to connect your ecu up to their vehicle and see if it does the same thing.at least that would rule the ecu out.

[clean_me]

At the risk of being called an idiot here, it's not the EGR valve, is it?

I had a very similar problem with a Primera that had 200K on the clock - the EGR valve was coked up and kept cutting out the engine at low revs. It would also intermittently turn the engine warning light on.

I don't know if the KZN130 has an EGR valve - I'm sure somebody will waste no time in putting me straight if it doesn't, though...

[TonyN]

If you've tried all the suggestions so far it wouldn't be overly expensive to just cut your losses and get a working used fuel pump and injectors and toss them on.

You need to start eliminating stuff, servicing done, bin the EGR, no fault codes so electrically ok, bin the immobiliser, then compression test and the fuel system.

Start cheap and work your way up.. ignition switch, spill control valve, fuel pump.

You don't say when it won't start for 10mins, if there is fuel to injectors while it won't start, if there is definatly get a compression test done you may have a knackered head gasket and it losses compression when it heats up and things expand.

Wouldn't hurt to blow down fuel lines back to tank in case they are blocked, but our truck does this sometimes due to crap in tank and you get a fault light when there is no fuel pressure.

[legocar]

Thanks to everyone for the advice, ideas, etc.

Looks like I'm gonna be busy for a few weekends.....