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Discussion Starter #1
New ip fitted Nov 13. Previous pump failed due to long term air in fuel. Primer leak. Approx 8 weeks ago I notice rough running while on the highway. Suspected fuel filer needed changing. I normally replace filter every 22500 and was not due for change. I carried on to next town. Replaced filter and all appeared okay. I notice that the ICV was lower, 28, than normal, high 30's. Over the last month the ICV has slowly dropped. 2weeks ago I replaced the filter again. At the beginning of the week it was struggling to make 20. Yesterday while driving it suddenly dropped to 4 and threw a MIL with limp. I stopped and checked the hose connections for loose. OK. I pumped the primer and there appeared to be no air. Cleared code and restarted. ICV back to 20 +. Over the next 20km the ICV slowly dropped until MIL light. Again struggled to town, 90km. Again replaced filter but no change. The car is now at the mechanic for further diagnosis. I have lodged an insurance claim.

2002 ZD30 auto- Dawes and needle fitted- EGR blocked-350000km on clock- oil change every 7,500 km- air and fuel every third oil change.

:(
 

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Gday Jim. I do remember your problems around the same time I also had my icv meltdown. OK this sounds suss bud and from my experience the low icv isn't always a buggered ip. I don't recall you having a lift pump.I limped home for 75 ks on 4% also. Since my carter instal my icv regularly idles 62% warm. 58% cold. First gear engaged 68%. A guru here kept trying to make me realise when I was discussing my trials and steps of solving the culprit of low icv..that something was amiss and more than likely not a cactus IP. Bottom line I've done a further 15 thou ks and the truck hasn't driven better.find my icv thread and have a read again. Ill be positive here for you Jim and say it might be something overlooked? And what is chewing out your IPS if its so. We have to find the cause before pouring more heartache into IPS every 6 months.
Cheers
 

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Y2KGUII ZD Wgn
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That thread is in the archives along with some other interesting VP44 info.
 

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Discussion Starter #5
Original IP failed at 300,000. Problem found was long term air through primer. Stopped in at mechanic today. He found no contamination in fuel filter. Only done 500 km since replacing. ICV sits at 8 % idling and the motor is a little rough. Rev to 1500 and ICV goes up to 10 then drops back to 7. If held at high idle using warm switch it slowly drops and in less than 5 minutes it is back to 4 and the MIL light is on with associated code. This was the same with the lasts IP.
 

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what was your ICV when the new IP went in? You have replaced the primer pump head? Ran clear lines to and from IP looking for air bubbles? have a new oring (gasket) on the primer head? checked your intank pickup for cracks? hows the condition of clamps and hoses back there at the tank?(the rubber ones) hows the condition of your metal fuel lines any dents, cracks? hows the one way breather valve to your tanks? do you get a whoosh or a suck when you open your tank caps

Got a Carter pump? put pressure up it arse and see whats doin
 

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cool, best to spend a hundred clams and pressure that pup to see any tell tale signs of leaking, than bend over again hey? that would be my first port of call along with checking everything else on my post above.

dont forget the spill line...it will need re-routing back to tank :)
 

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Y2KGUII ZD Wgn
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Agree, even if it doesn't do the trick it will benefit the new pump, if he keeps it and goes that way.

It sounds like the original underlying problem remained, we know air creates damaging heat in the pump, this could have continued and it's not easy to pick air leaking in but it is easy to spot fuel pissing out (as you know :)).
 

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What fuel filters are you running each time? Try Oe if not as mine played up when put aftermarket one on.
 
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Discussion Starter #11
Have in line marine filter after primer. This has clear housing and approx 45mm long with clear housing. I have removed the filter and use this for constant monitoring for air in fuel. Primer goes hard after 2 strokes. Fuel filters have all been genuine after reading comments elsewhere last year. Filter install 500 km ago was not genuine but was all I could get.
 

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ok, whats the flow rating on the secondary filter housing, I know the filter is out but the VP44 doesnt like any restrictions especially without a lift pump.Has this been on all since the new IP? trying to eliminate causes here bud, because you don't want a 3rd IP
 

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Update. Today the mechanic has been everything he can think and recommendations from the diesel specialist. The lift pump was not fitted but the fuel tank was pressurised using air. This made no difference to the ICV reading, 8 at idle falling to 4 when revved, so the pump is being pulled and taken to the diesel specialist. If he confirms the fuel contamination then insurance will pay for the new pump, labour and associated costs, less $600 excess. Once it sorted I will look more at the lift pump installation.
 

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Y2KGUII ZD Wgn
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Update. Today the mechanic has been everything he can think and recommendations from the diesel specialist. The lift pump was not fitted but the fuel tank was pressurised using air. This made no difference to the ICV reading, 8 at idle falling to 4 when revved, so the pump is being pulled and taken to the diesel specialist. If he confirms the fuel contamination then insurance will pay for the new pump, labour and associated costs, less $600 excess. Once it sorted I will look more at the lift pump installation.
Mate don't forget to keep us in the loop, we like to add as much info as we can to our existing VP44 list :).
 

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Discussion Starter #16
Pump went to diesel specialist today. He remove a plate and all was clear. Removed the next plate and found what looks like metal shaving. He believes the pump has disintegrated. The pump is now on its was to MTQ, who originally supplied it. They will report back tomorrow. In the mean time the main tank has been dropped and is perfect inside with no sign of contamination or rust. A replacement pump has been ordered and will be fitted. I expect to be back on the road Friday.
 

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oh, what chamber was the shavings in do you know? any pics at all.
 

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Discussion Starter #20
We'll it looks like I have been screwed. As far as the mechanic and I new it was a NEW IP. Today I was told by the supplier that it was an exchange unit from MTQ. RACQ contacted MTQ to collect the IP for their own people to look at. MTQ have advised that the pump is now in pieces all over there workshop and that is not possible. I paid $2900 for the pump when compared with others advertising reconditioned pump. Bailey Diesel offer 2year 100000 km warranty for recon pump. MTQ 3 months 20000 km. I will be talking to my supplier and MTQ tomorrow. Neither I or my mechanic are very happy as it looks like I am up for $4500 for a pump and labour as RACQ will not consider a claim with out seeing the pump. OTHERS BEWARE!!!!!!!!!!
 
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