Ford fusion diesel fuel leak

[Burnerman]

Thanks for all your replies.

When the injector seal goes doesn't this make a sound, I think it's called chuffing? I couldn't hear any noise.

The garage said the problem was a pipe, which they clipped back together, assuming this is correct, what would make it unclip and leak again? Can an injector leak back into the fuel pipe and build up pressure?

Cheers, Camerart.

I certainly cant disagree with this, but according to Ford, the leak is so slight as not to lose compression, but diesel fuel tends to get blown back around the injector crazy I know.....a bit like running a petrol car engine with a loose plug - and oil gets around it, somehow.
The symptom I found with this engine.....injector well full of diesel, blow it away with compressed air. After 15 minutes of running, the well is full again. No leaks at the leak off pipes! Swapped injector - just the same. Renewed the copper seal - just the same. You would think that fuel was leaking out of the side of the injector...but it wasn't!
One of life's great mysteries!
John

 

[camerart]

Thanks for all your replies.

When the injector seal goes doesn't this make a sound, I think it's called chuffing? I couldn't hear any noise.

The garage said the problem was a pipe, which they clipped back together, assuming this is correct, what would make it unclip and leak again? Can an injector leak back into the fuel pipe and build up pressure?

Cheers, Camerart.

I certainly cant disagree with this, but according to Ford, the leak is so slight as not to lose compression, but diesel fuel tends to get blown back around the injector crazy I know.....a bit like running a petrol car engine with a loose plug - and oil gets around it, somehow.
The symptom I found with this engine.....injector well full of diesel, blow it away with compressed air. After 15 minutes of running, the well is full again. No leaks at the leak off pipes! Swapped injector - just the same. Renewed the copper seal - just the same. You would think that fuel was leaking out of the side of the injector...but it wasn't!
One of life's great mysteries!
John

Hi John,

Would the symptoms you describe, also show a leak (Big leak) if I pumped the rubber primer while the engine wasn't running, as this case?

I live 150 miles from the car and my sister, so all I can do is ask questions for her.

Cheers, Camerart.

 

[Burnerman]

The leaks I've been blethering on about only refer to when the engine is running, so if your leak occurs only when the priming bulb is squeezed, then its got to be a leak between the bulb, fuel filter and then on to the injection pump i.e on the low pressure side of the system.
Therefore, we need to inspect for perished or rubbed pipes, (the latter being the most likely), a filter incorrectly replaced or leaking pipe connectors (rather unlikely that one, so long as they have been carefully removed and replaced).
John

 

[camerart]

The leaks I've been blethering on about only refer to when the engine is running, so if your leak occurs only when the priming bulb is squeezed, then its got to be a leak between the bulb, fuel filter and then on to the injection pump i.e on the low pressure side of the system.
Therefore, we need to inspect for perished or rubbed pipes, (the latter being the most likely), a filter incorrectly replaced or leaking pipe connectors (rather unlikely that one, so long as they have been carefully removed and replaced).
John

Hi John,

We're closing in Ok, the leak is when the priming bulb is squeezed, also when the engine is running, so now we have eliminated 'blowback' it seems to be after the mechanical pump, and before the injectors. I don't know what all this looks like. If there is a link to a diagram, it would be handy.

Cheers, Camerart

 

[Peter.N.]

Hi John

I have tried running it without the bar and there is nothing coming out at all, I disconnected the pipe under the bottom of the handle and oil is flowing freely from that.

How is the pump held in? I can't see any screws.

Peter

 

[Burnerman]

The leaks I've been blethering on about only refer to when the engine is running, so if your leak occurs only when the priming bulb is squeezed, then its got to be a leak between the bulb, fuel filter and then on to the injection pump i.e on the low pressure side of the system.
Therefore, we need to inspect for perished or rubbed pipes, (the latter being the most likely), a filter incorrectly replaced or leaking pipe connectors (rather unlikely that one, so long as they have been carefully removed and replaced).
John

Hi John,

We're closing in Ok, the leak is when the priming bulb is squeezed, also when the engine is running, so now we have eliminated 'blowback' it seems to be after the mechanical pump, and before the injectors. I don't know what all this looks like. If there is a link to a diagram, it would be handy.

Cheers, Camerart

On these systems, any fuel that is pumped from the fuel tank to the injector pump but isn't used. simply returns to the tank - its a sort of continuous circulation system. Therefore, I guess the leak is on the return pipework just after the injection pump!
Its still on the low pressure side here.
John

 

[Burnerman]

Hi John

I have tried running it without the bar and there is nothing coming out at all, I disconnected the pipe under the bottom of the handle and oil is flowing freely from that.

How is the pump held in? I can't see any screws.

Peter

To access the pump Peter actually means a major strip down - including taking the machine handle off which is a pain in itself.
The pump is a press fit in the housing, and to withdraw it requires a screw to be fitted into the non drive end. The head of the screw is then levered upwards (Stihl special lever is used here) to withdraw the pump.
Oh joy!
John

 

[Peter.N.]

I have got the handle off John - I know what you mean! Is the end of it where the pipe from the tank connects?

Peter

 

[Peter.N.]

Sorry to pester you again John, especially on this forum but the spring on the nylon worm drive gear isn't engaging in anything, which is presumably why the pump isn't working, I can't see anything for it to engage in, its just running round loose or not as the case may be. I can't see anything on the underside of the clutch for it to engage in, but I can now see the principle.

Peter

 

[Burnerman]

Hopefully I'll be able to help Peter, but be aware this is from memory!!
Outer clutch drum held on by 'e' clip, then there's a washer and the outer drum comes clear with its roller bearing.
Behind is the centrifugal clutch unit (3 shoes) left hand thread. Behind this is a large dished washer marked TOP for some reason.
With this off, you should see the white nylon worm. The spring thing is wrapped around the outside of the worm, so when the spring turns, the worm naturally does too, spinning the pump pinion.
Now, the spring thing has an end shaped a bit like a question mark, and that is the end that engages in the slot on the outer clutch drum. (The slot actually has a scribed line marked on it, but the drum won't go back on unless the spring is engaged).
Am I close to the mark? Maybe the end has gone from your spring!
John

 

[Peter.N.]

Hi John

Your description is spot on but on mine there is nothing for the question mark spring to engage in, the bottom side of the clutch is exactly the same as the top with just three gaps between the weights, nothing in which the spring can engage, do I have something missing? That is exactly how it was when I took it out, the spring was moving about not fixed to anything. I could bend it to locate in one of the gaps in the clutch but that might possibly interfere with it.

Peter

 

[Burnerman]

Can you look at the outer clutch drum Peter - the bit that has the chain drive sprocket on it.....we are looking for a slot in it?
The central bit, that screws onto the end of the crankshaft and has the three shoes plays no part in this.
John

 

[Peter.N.]

Thank you John, the light has dawned, I see how it all works now, presumably the pump is faulty then.

Peter

 

[Burnerman]

I must point you in the direction of a firm called garden-hire-spares Peter - they have an ebay shop and if you can find their home page they have a listing of many Stihl machines......all pattern parts but quality and be amazed at the prices!
You'll find your pump for less than a tenner and also the spring thing that drives the worm.
(I've just ordered a piston and barrel kit for a TS400 - the stone cutting saw. Comes complete with rings and gudgeon pin for £25 )
Unbelievable - and I've fitted lots....at least 20 or so different makes.
John

 

[Peter.N.]

Thanks John, I already have a pump on order and that was less than a tenner, all I have to do is get it out! I also have this Ryobi chainsaw on a stick that wont run .......

Peter