Archived need help/fuel system?

[Hpark]

Engine starts and runs OK under no load, however, at full throttle, the engine begins to lose power, sputters and stalls out. difficult to restart. After repeated attempts, the engine starts and runs ok as long as not under load or full throttle. I've changed the fuel filter element and seemed to have improved some what, but it stalled again climbing a moderate hill yesterday. I live and work in Maui,Hawaii, travel from elevation 3,500' elevation down to sea level daily, I've purged for water in the fuel filter, but did'nt solve the problem.



Could it be clogged lift pump screen or the pump strainer? Not able to deliver high fuel flow? Fuel line crack sucking air at high flow? Any way to test or diagnose? Any assistance is much appreciated, as this is my daily ride.



97 3500 4wd 5spd QC Laramie SLT 147k miles BD brake, K&N, Bank's Power Pack

 

[LarryB]

A fuel pressure gauge here would sure help.



Could you have gotten some bad fuel. I've had symptoms like this when I get fuel with a bad case of alge. It plugs the pickup screen. Usually high power problems are caused by a blockage. Starting problems can be caused by air leaks.

 

[Hpark]

fuel pressure gauge install?

Where should the fuel pressure gauge be placed? Any info on the gauge and install would be much appreciated.

 

[Andy Redmond]

Well first off you are likely not going to find many metric fittings in Maui, beautiful place but inconvenient for wrenching at the last minute. Oh, that's why it beautiful.



Actually, I'll come check it out for you if you can get me a ticket, of course the wife will want to come too and see the sights again.



Seriously, I think you got a batch of bad fuel.



I have a male metric to 1/4 " male sae flare adapter for the plug on top of the banjo bolt nearest the radiator that is the filter outlet (fuel water seperator). It's M6*1. 0 thread. .



Probably the easiest thing for you to do, is to remove the banjo bolt with the 19mm head that goes into the side of the injection pump, being careful not to lose the sealing washers on either side. Chuck it up in your bench vise and drill and tap the center for 1/8 pipe, etc. get a pipe plug and some liquid teflon (use sparingly) while your at the hardware store, Napa, etc. also pick up some fittings and some hose and a gauge face (liquid or silicon filled, reduces the lift pump pulses). I bet you have a good hose/fitting store (parker hoses?) over near the Maui airport.



Replace the banjo bolt, attach your gauge, you might have to hit the primer on the lift pump a few times as it might have lost its prime. Start it up and you should have near 20 psi at idle and 25-30 when its reved up.



If not you have filter restriction or plugged fuel plumbing, a weak/bad lift pump or bad overflow valve.



Get some biocide at the auto store for diesel, it will help absorb and pass the algae growth in the tank. If its very bad you might have to drain and drop the tank for cleaning.



A caveat for permanent gauge mounting, use a snubber, isolator to electric gauge etc... we don't want any fires.



Good luck, Have some mahi-mahi and pineapple for lunch for me!



Andy

 

[Hpark]

gunked up fuel screen!

Andy, thanks for the info on the gauge install, I will implement it on reassembly. I think I'll replace the rubber fuel lines as well.



I discovered that the fuel screen was gunked up with so much black stuff, both flaky and slimy, I'm afraid that I may have to drop the fuel tank and clean the pick-up screen as well, any suggestions on how to perform the cleaning procedure?