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Old 22nd July 2014, 07:56   #1
falcoron
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Default major issue with fuel tank help required plz **Sorted**

Ok let me start at the beginning, this will be a long explanation but please read on and offer help if you can.
When i bought mt 2002 cdt saloon over a year ago i took it to Brian for a remap, i got the 160 map and a good check over with the T4 all was great especially the injectors, so was happy but the T4 said the rear fuel pump was not working, so ok i've done that before so no issue.
Got home, bought a new pump and when i went to replace it i got a shock! nothing in the tank!, all internals gone, ripped out! so with a little asking about i got a good replacement tank with all internals intact, then i fitted the new pump to it and replaced the tank. the previous butcher had rerouted the pipwork all different so getting this right was a pain but with help here and with rimmers drawings i got all the routing correct. The other issue was the fuel cooler rad was also missing ( butcher had removed that as well) and the return pipe was blocked off with a bolt. I got advise from rover specialist here in Northern Ireland ( who gives cracking service to us here over the years and is very knowledgable) he has been removing and rerouting these leaky fuel cooler rads for years with not 1 going wrong. So with his advice i unblocked the return pipe and rerouted this back to the tank, he told me these were really only for very hot countries and would never be required here with our climate, he even showed me 3 cars he had in stock all done and all had completed over 20k miles since with no ill effect at all.

So what is my issue, well car runs superbly well, im getting good MPG, for a year now i have had no issue at all bar the under bonnet pump going a few weeks ago and is now replaced with a mekon one and running perfect again.
now car was running great before and after the replacement tank, in fact no issue at all for nearly a year, so these issues now are quite new and with nothing else done in that area this is a complete mystery!
The issue was first noticed a few months ago with pressure gathering in the tank, everytime i released the fuel cap i got a large gasp, think the tank is in vacuum so the gasp is for outside air. I drilled a v small hole in the cap and problem gone! all good except the diesel is seeping from the cap and staining the rear panel. Bought a new cap from rmmers and im back to pressure and a little staining as well? been trying to get this sorted for a while with no luck although ive pnly been asking not actually doing anything.
Now yesterday i removed the rear wheel liner and disconected the breather and the return pipes blew down each and no blockages at all. as an experiment i disconnected the small return pipe ( that would have run into the cooler) and blocked the ends up, they way it was before the new tank went in. Took for a drive and as always ran perfectly well, i then stopped and released the cap to see if still being vacuumed and it was, no difference? I will reconnect this return pipe tonight.
Also the car used to fill easily with no kick back from the garage diesel pumps, now it takes for ever and getting slower and slower!
This morning i could only get £17 in her the she spilt out the neck all over the car and ground! its a real pain in the ass! can't understand how. It was fine for almost a year and all of a sudden she started to presuurise the tank and get very hard to fill. can any one help please its a real mystery!!
Ron
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160 T4 remap, HR lowering springs, 11 spoke 18" wheels fitted & refurbished, premium bumper and MG7 grill, rear MKII ZT bumper, rear ZT boot lid spoiler, Chrome body trim and handles colour coded, 190 brake upgrade, gold MTEC grooved and slotted 190 discs EBC pads
handbrake mod, bonnet release mod, vitron O rings mod,
new diesel pumps front and rear,

Last edited by falcoron; 22nd July 2014 at 09:11..
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Old 22nd July 2014, 09:09   #2
Mike Noc
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If the small vent pipe running to the expansion tank in the picture is clear then that only leaves the expansion tank itself or the outlet vent pipe from the tank to atmosphere Ron.

If you remove and up-end the expansion tank it sounds like it incorporates a rollover valve.

[IMG][/IMG]

You mentioned removing and blocking the pipe that usually goes to the fuel cooler assembly. That runs from the expansion tank and isn't a return pipe but the vent to atmosphere, so should be left open.

Last edited by Mike Noc; 22nd July 2014 at 09:18..
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Old 22nd July 2014, 09:24   #3
falcoron
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Quote:
Originally Posted by Mike Noc View Post
If the small vent pipe running to the expansion tank in the picture is clear then that only leaves the expansion tank itself or the outlet vent pipe from the tank to atmosphere Ron.

If you remove and up-end the expansion tank it sounds like it incorporates a rollover valve.

[IMG][/IMG]

You mentioned removing and blocking the pipe that usually goes to the fuel cooler assembly. That runs from the expansion tank and isn't a return pipe but the vent to atmosphere, so should be left open.
thanks Mike,
mine has 3 pipes running into or from the expansion tank, there is 2 corrugated pipes running side by side one is a breather the larger one and the other is the return to expansion.
there is another fine pipe that was blanked by the previous guy i returned that to the tank, think that is wats wrong i will get a photo later and post it i have the liner removed so if i send a photo you will see whats what think i might have the breather going to the tank as a return so that may well be the issue, i was scared to lrave anything unconnected in case i caused a diesel spill. hope thats it as that will be an easy fix.
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Upgrades so far:
160 T4 remap, HR lowering springs, 11 spoke 18" wheels fitted & refurbished, premium bumper and MG7 grill, rear MKII ZT bumper, rear ZT boot lid spoiler, Chrome body trim and handles colour coded, 190 brake upgrade, gold MTEC grooved and slotted 190 discs EBC pads
handbrake mod, bonnet release mod, vitron O rings mod,
new diesel pumps front and rear,
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Old 22nd July 2014, 09:31   #4
Mike Noc
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Sounds like a bit of re-routing and all should be well.

We all love a quick and cheap fix.
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Old 23rd July 2014, 06:41   #5
falcoron
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Quote:
Originally Posted by Mike Noc View Post
Sounds like a bit of re-routing and all should be well.

We all love a quick and cheap fix.
Sorted i think!!
the breather for the expansion tank had been blocked by the previous idiot so the tank was pressurising, i opened this last night and the tank breathed a sigh of relief, i drove to work this morning and opened the fuel filler to check if pressurised (as it would have been usually)
and nothing, all good so far, think this might be good as new again. Hope that sorts the filling issue as well as that is a real pain, but my hopes are high.
Thanks for the help Mike appreciated mate.
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Upgrades so far:
160 T4 remap, HR lowering springs, 11 spoke 18" wheels fitted & refurbished, premium bumper and MG7 grill, rear MKII ZT bumper, rear ZT boot lid spoiler, Chrome body trim and handles colour coded, 190 brake upgrade, gold MTEC grooved and slotted 190 discs EBC pads
handbrake mod, bonnet release mod, vitron O rings mod,
new diesel pumps front and rear,
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Old 24th July 2014, 00:31   #6
Mike Noc
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You are more than welcome Ron. Glad you are sorted.
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Old 24th July 2014, 09:55   #7
DMGRS
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Unfortunately with a lot of our cars being over 10 years old, we're likely to find a good few with some awful bodge-jobs - I've seen some corkers in my 75/ZT ownership!

Cardboard stuffed into a Master cylinder, bumper glued on, missing PCV Filter... the list goes on...
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