Broken fuel pump..again. Why?

[Modena]

Before reading, I'm Dutch. Do not mind the spelling :lol:


Dear Puma friends from across the canal!

I've got a Puma 1.7 (2002) and recently I had some problems with the fuel pump. A couple of times when I tried to start it (spread over a number of months) it would not start and the pump would not make any noise. When I checked the fusebox, the fuse of the fuelpump was broken.
I put a new fuse in and the Puma would start like a new one again! I knew something was clearly wrong, but this quick fix was easy! So, the third time it happend, a new fuse didn't help. It would break immediately after starting my Puma. I than realised my fuelpump was definetely broken and I needed a new one.

Luckely I had some spare parts from a 1999 Puma. My Ford dealer told me the pump would probably be the same, so I could use this one. When I disassembled my fueltank and took out my original fuel pump, I saw that it was al little bit different but the main parts looked the same. So I put in the “new” (secondhand) 1999 fuel pump in the tank.. et voila! My problems where solved!

For like four months yeah… because last weekend I was driving my Puma down the highway. After like 40 kilometres it started to hesitate when I put down the throttle. First little hiccups, strange… Than more and more times no gas under the throttle. When I wanted to pass a truck, I didn’t know if we were gonna make it! Untill there was no acceleration at all. I had to put my Puma on the road shoulder! So we towed him home :’(

Complications this time? The fuel pump worked, but made a strange noise. So we pushed it on the driveway of our house and my boyfriend asked me (because it was heavy to push) to start the Puma en try to give a little gas. Amazing, it started and drove all by itself without us having to push! When we parked it, we tried to start it a couple of times. My Puma would start, but as soon as I would step on the gas a little it would start to hiccup and die immediately. Try starting again. This time it did not start at all. Try starting again, hiccup hiccup. Overall not drivable, not even for a few meters.

So now our guess is that I’ve got a little dirt in my fueltank?? That would explain why my Puma “eats” fuel pumps. Has anyone ever experienced something like this? Any ideas? Perhaps something else is wrong? I don't use my Puma that often, I've got a daily. The Puma is my weekend-car Has that got anything to do with it perhaps?

Like to hear from you guys, thanks! :grin:

 

[DOH]

When was the fuel filter last changed? It seems extremely likely that it is badly blocked. That would explain why the car restarted after a while, because it had time to seep through. To help you locate it, It is the canister fitted on the front of the fuel tank on the nearside. I presume your car is left hand drive. It is therefore on the drivers side.

 

[Modena]

Good question. I bought my Puma december 2008 and since then I've never changed the fuel filter. Most likely it has never been changed at all (I'm the second owner).

I'm looking for a secondhand fueltank and fuel pump on the internet right now. I'll get myself a brand new filter, clean that secondhand fueltank at home and put the pump in it. Everything ready to mount when I go to the garage (friend of mine) :grin:

Then I've done everything I possily can I guess :grin:

Or do you think it's only that filter? My car indeed is left hand drive :wink: Thanks for the coordinates, I will definitely use them! That friend with the garage only works on Ford Escorts :wink:

 

[DOH]

I would advise you to change the filter first before replacing the fuel tank and pump. It is relatively easy to change. It appears that because the filter is blocked it will either have strained the previous fuel pumps and caused the fuses to blow, because it has been fighting against too much pressure to force fuel through the filter. However,there is a possibility that the fuel pump is still ok and you should first fit the new filter and try out the car. If the pump is ok and with a new filter fitted,the cars performance will be dramatically transformed.

The fuel is the only lubricant for the pump. People who regularly run there cars low on fuel i.e in the red on the gauge, will cause damage to their fuel pumps plus it sucks up any dirt from the bottom of the tank and blocks the fuel filter. These should be changed at least every 40K miles.

Be aware, that there may still be be residual pressure in the fuel lines . So I would advise:
1) To remove the fuse for the fuel pump (its in the engine bay fuse box ) and crank the engine for 30 seconds to lose the pressure through the injectors.

2)Wear glasses or goggles to prevent fuel spraying into your eyes. The connectors on the filter are usually easier to remove than those fitted to the fuel pump.

Let me know how you get on. :thumbs:

 

[Modena]

Sooo, we've changed the fuel filter today. No results!
It was even worse when we got to the car today, wouldn't start at all!
Fuel pump sounded good though...

So we changed the fuel filter and saw the fuel lines were rotten too. The one from the pump to the filter, and the one from the filter to the engine. Got rotten because of Tectyl! My Puma got a Tectyl anti corrosion treatment a few years ago. Apparently to much Tectyl on these lines. So called my Ford dealer for these new lines, my gosh they're expensive too! €121,27 together, two lines! Anyways... I just need them right....

Okay, my Puma won't start at all right now. What could possibly be the problem? Secondhand pump and tank are on the way. New filter is already here and the lines I still have to order. What a day!

 

[DOH]

Hi

1) This may appear a silly question, but did you put the fuel filter on the correct way round. It has an arrow on it for direction of fuel flow? It is important that is correct. The arrow points to the pipe heading towards the front of the car.

2) Do you now still hear the fuel pump buzz for a few seconds when you turn the ignition on, It should have buzzed for approximately 7 seconds as it filled up the new fuel filter, you said the pump sounded good , that will be because it was filling the filter, but does it buzz now for a couple of seconds when you turn on the key?
If not check the fuses again & look at Point 4) below.

3)Anyway, there is a fuel pressure regulator, it is fitted on the right hand side of the fuel rail , which has a diaphragm inside. It is used to maintain the pressure in the injector fuel rail. It has a vacuum hose fitted to it. If the diagraphm is faulty or stuck open then the fuel from the fuel line will pass straight back through the fuel return pipe back to the tank without there being enough fuel pressure to fire the fuel injectors. You can test the fuel pressure in the injector rail by removing a blue plastic screw cap (it is similar to that fitted to the valve on the tyres). It is located on the left hand side of the engine.close to the head at the left side of the inlet manifold You can fit a tyre pump pressure gauge to this to check that you have sufficient fuel pressure when the pump is switched on, I haven't my data book handy, but I would expect approx 2.5- 3 bar pressure. If the pump is buzzing and provided the fuel lines are not leaking if you get low pressure readings then you could also try giving the diaphragm metal casing a gentle tap with a small piece of wood , it may be just stuck instead of the diaphragm being torn.

If the pump isn't buzzing try this:
4)There is a fuel pump cut out switch in the foot well through a round hole in the carpet on the left hand side on the "A" door pillar. If the pump isn't buzzing then perhaps that just needs resetting. to do that turn off the key in the ignition switch position 0 push the button down turn key to position "11" . After a few seconds return key to position"1"

Check for fuel leaks under the car especially near the fuel lines that are suspect.
With regard to the fuel lines, they are black plastic, I replaced 1 of mine 4 years ago because it was leaking where it fitted to the filter. I have no experience of using the product Tectyl as I have never seen it for sale in the uk, however I googled it and it appears to be very similar to Finigans Waxoyl , a wax based product that is thinned with white spirit. My car has been waxoyled and that hasn't caused the plastic fuel lines to deteriorate. It is more likely to be related to the age of the car than than the tectyl.


5) If you have a fuel pump buzzing for a few seconds , then have you checked that you have a spark at the plug leads?

6) I note that you have another daily driver, perhaps its diesel? Hopefully, you put petrol and not diesel into the tank, check your last refuel receipt for the Puma ?

I know that it is an inconvenience to you,but persevere with this, because when you do get it going , it will be running better than it did before it failed.

By the way ,The reason that there was a difference between the fuel pumps when you changed it , is because the early pumas have an analogue mileometer (odometer) and the later Puma late Oct/November 1999 onwards had a digital odometer :thumbs:

 

[Van_Dammesque]

Mine went knackered had it replaced, but they also found an earthing problem, something to check as well.

 

[Modena]

Hello there! Thanks for your help!

So I've been at work this whole week and my Puma is parked (broke down) at my boyfriends place. We still live at our parents. So he's been checking the Puma. I'm going there tonight to see things myself.
I'll print your post and we'll check everything! i'm so curious what the problem is!

1) My boyfriend changed the fuel filter. He knows what he's doing (he's got five Fords and is pretty handy with this stuff) and he told me he put the filter on the right way
2) The fuel pump is buzzing when he turns the ignition. Not sure for how many seconds. I'll check that tonight.
3) We'll check the fuel pressure too! Great idea!
4) I was being told the pump is buzzing I'll check for fuel leaks!
5) And check the spark at the plug leads, haha! Al lot of checken, very good!
6) My daily a 1996 Ford Fiesta! A daily not because of all the miles (I only make about 21km a day), but because of parking dents Hate them, don't want them on my Puma. And ofcourse the brine (is that how you call it in english? salt!) in the winter. Anyways it's not a diesel :lol: so same fuel!

I'll be back!! With more information.. I hope. Thanks so far! :grin: :grin:

 

[DOH]

Hi

Both cars look very smart.
Thought I would mention the types of fuel, to rule that out.

Yes salt is the correct word ,that causes the cars to rust.

A very common problem with the zetec engine is a leaking rocker cover gasket,it maybe that when he goes to check the spark plugs that the leads are immersed in engine oil from the leaking rocker gasket. That would also stop the engine starting as the leads spark would be tracking out and therefore not reaching the firing end of the spark plug

Obviously you can test for a spark by removing 1 plug lead and putting a spare spark plug( from any car is fine to test) into it and earth the threaded part to the engine and observe (see )if there is a spark jumping across the electrode gap. Caution!Make sure you are not touching the spark plug lead . Otherwise you will get a nasty shock. It will travel through the insulation of the cable

If you have a spark and the fuel pressure seems reasonable, then take put all 4 spark plugs and observe what they look like,

You could post a close up photo of the firing end of the photo .If they are very black /sooty you could clean them up and try and start the car.

If it is an early Puma with clip on Type type leads at the coil pack end of the lead, the engine runs best with a plug gap of 1.3mm.

The later coil pack has ordinary push on type leads ,Plug gap 1.0mm


The braided copper wire earth lead at the back of the engine to the bulkhead by the coolant bottle is very important that it is good, not partially torn or broken. This affects the quality of the spark.

 

[Modena]

Hi there, again :grin:

I had the rocker cover gasket changed last year, because it was leaking indeed. So that can't be the problem either :grin:

So, we had a good look at the Puma last Friday. The fuel pump buzzed for a few seconds when I turned the ignition on. Sounded good. But when I tried to start the car, the engine would turn over but would not start.

So we checked the fuel pressure (on the left hand side of the engine), like you mentioned. No pressure at all! We had a spark though! Then on the other side of the engine we pulled off the fuel line that provides the fuel for the engine... we tried to start the Puma... no fuel came out!! So no fuel is transported to the engine. There's a new filter on... so we truely think the pump is broken. Yesterday a new (secondhand) pump arrived and I also ordered another fuel tank. I'll clean this at home and then take the whole 'package' (pump + tank) to the garage.

I saw that the fuel lines were not damaged (by the Tectyl), but the connection-part. Everything was stuck, covered in sticky greasy tectyl! Yuck! So I also have to order two new fuel lines.

Short one, from pump to filter

Long one, from filter to engine

Monday I'll hear what these fuel lines will cost me (with discount, a friend of mine works at Ford) and then I'll order them!!

 

[DOH]

Yes it does sound like the pump has failed.Did you try disconnecting the pipe that goes from the fuel pump to the filter to see if any petrol comes out at all into a container? If it does let fuel out Then reconnect it and try the pipe after the filter?

 

[Modena]

Not sure if any petrol came out. We'll check.

In the meanwhile, what would be the best way to clean my "new" fueltank. Hmm...
Research on the internet provides me with the following: http://www.forteuk.co.uk/" onclick="window.open(this.href);return false;

Forte Fuel System Cleaner (Dutch version) http://www.forte-nwe.nl/NL/Forte-Producten/Auto/Brandstof/Fuel-System-Cleaner.html" onclick="window.open(this.href);return false;

But to use this only to clean a fueltank? Another website/forum said you could rock pebbles/stones around in the tank with water and soap.

Any experience with cleaning a fueltank?

 

[DOH]

Hi
You don't need to buy a Forte product, that's a very expense and unnecessary approach. I recall when i did mine it was not possible to get the last bit of fuel out as part of the fule tank filler pipe protrudes inside the tank. So when you tip the tank upside down, some fuel remains in the tank.

I wouldn't use water and soap. Petrol itself is a good cleaning and degreasing agent You could try a kitchen dish washing brush with long handle through the fuel pump top plate opening.
The nylon bristles may dissolve though from petrol. You can use Diesel or paraffin but Petrol should work ok. Blow out the debrit with an airline that you can't soak up using kitchen towels.

Make sure the outside of the tank is rust free or treat and repaint. the top of the fuel tank corrodes due to collecting salt off the road .

 

[Modena]

Cleaned! With petrol :grin: Just a little debris came out the new tank. This amount would never have caused trouble... but it's out now! So still waiting for my fuellines. Than we can finally (hopefully) fix my Puma!!! :grin:

This new tank looked good, little rust. The bottom was black, looked like Tectyl again!
I'll take care of the rust before we mount it!

 

[DOH]

I would also recommend whilst you are waiting for your replacement fuel lines , charge the battery up with a trickle charger. This is because you have been turning it over without it starting. If the battery voltage is low, then when you try to start the car, all of its energy will be used up by the starter motor and the result will be a smaller spark to the spark plugs

 

[Modena]

OK, I think my problems are solved. But it was quite a story :shock:

I will keep it "short". First the long fuelline (engine - filter) was not availabe anymore. I had to get a secondhanded one from the breakyard (1999). Then it turned out that my problem was a broken fuelsensor!!! It said my tank was half full, but in fact it was empty. I should have looked at the kilometers I had driven, shit! So my new pump fixed that thank gosh.

Then that secondhanded fuelline turned out to be the wrong shape. Ford has modified the fuellines as well, somewhere between 1999 and 2002. So with some hoseclamps we temporary "fixed" it. Then another Ford dealer (friend on Facebook) wanted to order the fuelline again, with other (American?) numbers. He tried, and succeeded! Now I had the right fuelline that luckely fitted. Very thankfull for that.

Next problem was a strange noise and feeling sometimes when I drove my Puma. Like I drove over these white marks on the highway. A bumpy sound and feeling. I thought it had someting to do with my wheels?! But what could that be, new tyres and restored alloys. They drove fine for over a year. Now this! Oh, and when I braked firmly, my car pulled to the left.

It turned out to be a jammed caliper on the right. We opened everything up and cleaned the cilinder. It now moved again. I bought new braking pads because the "old" ones (they were just a couple of months old ) had been bloody hot! Still my car pulled to the left when I braked. It seemed my right brakes still weren't braking.

OK, emotionally I crossed a line by now. When we fixed one thing, another thing appeared. Before this my Puma never had any problems, neverrr! Now it seemed like everything came at once. I was on a tight scheduele (sunday the European Ford Event is there) and I wanted EVERYTHING to be fixed, properly.

So I brought my Puma to my Ford dealer. "Please fix it :-( before friday :-( "
They bleeded the brakes (again, we'd already done that) and said the problem of pulling to the left was nearly gone. There was al little pulling left, but I could fix that with reeling off my braking discs (which were also just a couple of months old, but the right side also had been bloody hot!).

Soooooo..... it took them one day to fix it. I picked up my Puma and it felt good. I'm going to drive her up and down my work this week, to see if there's anything unusual left!

 

[red]

:thumbs: glad to hear that you're getting to the bottom of things!