Tourneo Connect TDCI 2007 fuel filter runs dry

[radumotoc]

Good morning,
So I have this issue with my Tourneo Connect TDCI, 2007, in which the fuel filter runs dry.
Replaced filter a couple of months ago. Checked the fuel lines around the filter, there are no leaks (visible).
I start the test with the fuel filter full. Engine starts, the fuel rail pressure is around 30000 at idle. At first, fuel rail pressure constant. Then after a few minutes starts to get variable, drops at times to around 25000 foe a second, then back to 30000. Then engine stops. Check fuel filter, almost empty.
If instead of leaving the engine idle, I drive the car around, revving to sometimes 3000, it's fine until I stop the engine for a few hours.
After being stopped for a few hours, the engine starts, runs for a few seconds then stops. Check fuel filter, it's empty, like it has been drained.
As I said, visually checked all the lines for leaks or signs of chafe, none found.
There is fuel in the tank, strangely enough, at the same level as a few months ago when I had the exact same problem. At the time, I filled the tank and the problem seem to have gone away... Obviously not.

My next step would be to replace the fuel lines to the fuel filter - since the filter runs dry, the problem must be between the filter and the tank, not between the filter and the injection pump...

A question regarding one of the fuel lines, namely one that has a T in it (return to filter and tank). Does that T have anything particular in it, like a non-return valve? Or is it just a simple derivation? In this case, the return line goes all the way down in the tank to prevent air from being sucked if the fuel level is low?
Another question regarding the fuel level sensor / pickup inside the tank - my understanding is it does not contain a pump, right? Would a crack in the pickup body or one of the hoses be consistent with this behaviour?

I would be grateful for any ideas to help me diagnose this issue.
Thanks

[metalworker0]

There have been reports in this forum of an air leak into the pipe as it bends under the bulkhead and crosses the big cross member .

you are not looking for leaks you are looking for pin holes that let in air..

if non found in that region ..i think you are going to be dropping the tank ..for more investigation.

These are the correct procedures from the ford manual on how to check for air entering the system: note ..this assumes its running, i don't know why it assumes this ....but that's all we have! ford manuals from before 1990 were much better !


A1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
CAUTION:
CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator
1
Protect the generator with lint-free material to prevent contamination (vehicles with 2.0 L diesel engine).
2
Using a suitable piece of clear plastic pipe, manufacture a pipe that may be installed between the fuel injection pump and the fuel filter return line.
3
Install the clear plastic pipe between the fuel injection pump and the fuel injection pump to fuel filter return line.
4
Start the engine, wait a few minutes and then visually observe the clear plastic pipe for signs of air ingress.
Are any signs of air present in the clear plastic pipe?
Yes
GO to A2. .
No
REMOVE the clear pipe and CONNECT the fuel return line to the fuel injection pump. For additional diagnostics for Fuel Charging and Controls REFER to Section [long list here]

A2: CHECK WHERE AIR IS ENTERING THE SYSTEM
1
Using suitable clean engine oil, apply the oil to each of the fuel supply and fuel return connections, unions and joints in turn and observe the clear pipe for visible signs of air after each oil application.
Did the amount air in the clear plastic pipe decrease when any of the connectors, unions or joints were oiled?
Yes
REPAIR the connector(s) or union(s) in question. Test the system for normal operation.
No
GO to A3. .

A3: CHECK THE FUEL FILTER HOUSING FOR SIGN OF AIR INGRESS
1
Ignition switch in position 0.
2
Disconnect the fuel injection pump return line from the fuel filter and the fuel filter to fuel tank return line.
3
Using a suitable connector, connect the fuel injection pump return line to the fuel filter to fuel tank return line.
4
Start the engine and observe the clear plastic pipe for visible signs of air.
Did the air decrease in the clear plastic pipe?
Yes
Air ingress is at the fuel filter or housing. REPAIR or INSTALL a new fuel filter or housing as necessary. Test the system for normal operation.
No
INSTALL a new fuel level sensor.

all the best.mark

[radumotoc]

Thanks for This Mark, I'll get to it

[metalworker0]

The leak I mentioned may be found inside a plastic clip that holds the fuel line in place.

ALL the best.mark