2.5D fuel filter, low revs running problem 1995 120 custom

[japster]

Hi,

this is my first post so please be gentle, I have a 1995 120 Custom with a 2.5 Diesel engine, not sure what type but it's playing up.

It's fine at high revs but misses and chugs at low revs, starts fine, idles fine.

Fuel filter ? Can someone tell me how to change it ? Photos would be nice if possible.

Also I can see Diesel leaking from a little rubber bung thing on the back cylinder (nearest the dashboard). I don't think its the injector but there is a pipe linking the four cylinders and it terminates in this rubber bung thing.

sorry for my lack of Diesel knowledge but this is my first one.

Cheers, any help appreciated

Craig

[MrMPuk]

From the sounds of it the fuel leak is from the injector leak off pipe but pictures are worth a thousand words and all that!

The year of your van I would say that your filter is the quick release type, these have the yellow collor around the top, if so it's just a case of turning this and the filter will just drop off, you might have the water sensor on the bottom if so you need to push the wire clip in and it will pull off, then unscrew the sensor and screw it into the new filter you will need to fill the filter with fuel before fitting to make it easier to bleed.

I will try and put some pics on, let us know if you get stuck.

[japster]

Hi MrMPuk,

thanks for the super quick reply, unfortunately the van (which we use for transporting our band gear) is down my drummers house so I can't take a piccy immdiately but I will tomorrow.

I remember seeing a kinda nut / clasp arrangement on the top of the fuel filter assembly. It also has a white plasic bit at the bottom of the filter which leaked diesel when I slackened it off.

Is this some sort of drain ? what's it for ?

The injector leak thing is on a cotton covered rubber hose that jumps from cylinder to cylinder and terminates at the back one. It's only dripping slightly. What's this hose for ? I assume the HP fuel injection goes through the rigid steel pipes ?

Cheers again



Craig

[MrMPuk]

The white screw on the bottom of the filter is a water drain. As I said wasn't sure if yours had the water sensor or not, your probably better off not undoing that with the leak as it's probably going to draw in air which could be the cause of the problems!

The cotton braded rubber hose is the injector leak off pipe but to be honnest any fuel leak is bad news and should be fixed as soon as!

[gazza]

air is getting in at the leak off rail bung, running up the leak off rail to no 1 making in run badly, replace this with a piece of leak off rail pipe bunged with a suitable sized pipe, while your at it replace the hole leak off rail, the cotton covered pipe is only a couple of quid a metre at a motor factors. also when you change your filter fill it up with injector cleaner then carefully fit it, this saves having to beed system and has the advantage of running neat cleaner through the injectors

[transitgeoff]

i think forget the fuel side(appart from the leak off leak)and then check out the EGR setting as i beleive the engine is "hunting" at low revs because it cannot get any air, when you give it plenty the wrongly adjusted butterfly is open so alls ok but at low revs the butterfly is shut so the engine cant breath, very common and an easy fix

[gazza]

http://fordtransit.org/forum/viewtopic.php?t=1409

see above

[japster]

Update !!!

I've stopped the leak and replaced the leak-off hose (as well as replacing the leak off caps) as I broke every one getting them off then spent the rest of the day scouring scrap yards as Ford kindly tild me they wanted £16 each for them.

Replaced the fuel filter and put it all back together to find it's still exactly the same

It starts and idles ok but misses like f**k upto about 2000 rpm then catches then revs fine. So I'm stumped again.

What's this EGR thing everyone is on about ?

Could this be the problem ?

Or have I missed something to do with bleeding the fuel system ?

Please help, I need this van for gigging

Cheers,

Craig

[transitgeoff]

already told you once that it wasnt the fuel side and that it was and still is the EGR,buy yourself a haynes manual or pay someone who knows

[japster]

Ok keep your hair on !

I only wanted to know what the EGR meant. Now I know. So that's what I will look at next.

I found it quite easily cause I burnt my arm on it on monday

I've also managed to download a CD image of the Ford TIS which I'll take a look at later, f**k spending money on haynes manuals or garages.

Thanks for everyones help,

Craig

[jay]

EGRbasicaly the egr valve allows a small amount of exhaust gas to flow back into the inlet manifold so that the exhaust emmisions are a bit cleaner.or that is what the tree huggers would lead everyone to know.but your problem sounds like the butterfly in the inlet manifold is not set right or the rod to it has come off!

[transitgeoff]

spot on jay