Hyundai Tucson Fuel Leak - Help needed!
Discussion
Hello, Can anyone give any pointers please??
I have an '04 Tucson 2.0 crdi that I foolishly ran too low on fuel. Since then it had been juddering, usually from a cold start. This would happen for about 10 mins until the car warms up then seems to be fine. It has gotten worse and now judders constantly on tick over. It seems as if it is on a loop, it runs fine then you can feel it building up then it judders like mad (at which point the revs seem to drop under 1000) and it just keeps doing that until I set off. Yesterday it was terrible and revs were dropping to about 500 and i thought it was going to cut out altogether but again once I was moving it runs fine. When it is moving it doesnt seem under powered or anything and i havent noticed it getting hotter than usual or using more fuel (mileage seems to be the same) but it does smell of fuel now and again inside the car but im guessing that could be the fan blowing it back?? I have had the bonnet up and the gear box seems to have a load of fuel sitting on the top of it. I have cleaned up the high pressure fuel pump as that had a load of fuel over/around it and left it ticking over but no fuel seemed appear until I ran it again. I have got a recon pump and swapped it over but it has made no difference to the juddering so i have swapped it back to my old one. There was also a good cup fuel of fuel at the back of the pump in a well on the engine. I have also swapped the fuel pipes. No lights have come on the dash so I cant trace it with any codes. Feel at a total loss with it! Please help!! I love my little car!
I have an '04 Tucson 2.0 crdi that I foolishly ran too low on fuel. Since then it had been juddering, usually from a cold start. This would happen for about 10 mins until the car warms up then seems to be fine. It has gotten worse and now judders constantly on tick over. It seems as if it is on a loop, it runs fine then you can feel it building up then it judders like mad (at which point the revs seem to drop under 1000) and it just keeps doing that until I set off. Yesterday it was terrible and revs were dropping to about 500 and i thought it was going to cut out altogether but again once I was moving it runs fine. When it is moving it doesnt seem under powered or anything and i havent noticed it getting hotter than usual or using more fuel (mileage seems to be the same) but it does smell of fuel now and again inside the car but im guessing that could be the fan blowing it back?? I have had the bonnet up and the gear box seems to have a load of fuel sitting on the top of it. I have cleaned up the high pressure fuel pump as that had a load of fuel over/around it and left it ticking over but no fuel seemed appear until I ran it again. I have got a recon pump and swapped it over but it has made no difference to the juddering so i have swapped it back to my old one. There was also a good cup fuel of fuel at the back of the pump in a well on the engine. I have also swapped the fuel pipes. No lights have come on the dash so I cant trace it with any codes. Feel at a total loss with it! Please help!! I love my little car!
Just because there isnt a light on the dash doesnt mean there arent any error codes. Something that shows live data would be useful - check fuel pressure readings, glow plugs thermostat etc.
Have you replaced the fuel filter and air filter? That would be my first act on any issue with poor running.
Have you replaced the fuel filter and air filter? That would be my first act on any issue with poor running.
Thanks for replying, replaced the fuel filter last week and the air filter was before Xmas. I can get it hooked up to a diagnostics kit tonight.
The juddering only started after it ran too low on fuel (lesson learnt there!) just at a loss as to where all the fuel is coming from under the bonnet
The juddering only started after it ran too low on fuel (lesson learnt there!) just at a loss as to where all the fuel is coming from under the bonnet
I believe these use the Bosch injector which is quite long & seals on a copper washer at its lower end. (A quick ebay suggests they also use the same daft injector clamp as the Mercedes).
Similar Bosch injector used on the Mercedes Sprinter & these are well known for these sealing washers failing. I've replaced 3 of the 4 on my own 52 plate Sprinter 2.2.
The genuine Mercedes ones are very hard & I eventually followed the advice here & have had no further occurrences:
http://www.mercedes.gen.in/mercedes-diesel-injecto...
When they fail they allow part of what's injected into the cylinder to be forced past the washer & you will get a build up of a black treacly crud around the injector body, referredd to as 'the black death'. When they really go you are likely to get quite a lot of liquid which on the Sprinter runs out of a rubber pipe at the back of the head & drips onto the undertray or the road. I think if the rubber pipe wasn't there it would just run down the back of the engine.
Symptom for the first one on mine was a strong smell of diesel in the cab whilst driving. Checking under the bonnet showed heavy vapour coming from under the plastic cover over the head & it wasn't until I removed that that the black death was visible - a lot of it too!
This can either be carefully chipped off or removed with thinners - which takes longer.
The injector can also be well stuck & it it won't come out when worked by hand DO NOT lever on the top of the head/rocker cover as the ally is VERY THIN. Using a spanner to twist can result in undoing the top of the injector.
I just refitted the clamp leaving the retaining bolt backed off a couple of turns to stop the injector being fired out & started the engine. Took a few goes on the worst one but it did the trick.
Alternatively get it done by a diesel specialist who should have the necessary tools.
A leak from the join of one of the metal feed pipes from the fuel rail to the injector will do much the same.
You need to inspect it all. Bear in mind you are working with very high pressures so take care.
Similar Bosch injector used on the Mercedes Sprinter & these are well known for these sealing washers failing. I've replaced 3 of the 4 on my own 52 plate Sprinter 2.2.
The genuine Mercedes ones are very hard & I eventually followed the advice here & have had no further occurrences:
http://www.mercedes.gen.in/mercedes-diesel-injecto...
When they fail they allow part of what's injected into the cylinder to be forced past the washer & you will get a build up of a black treacly crud around the injector body, referredd to as 'the black death'. When they really go you are likely to get quite a lot of liquid which on the Sprinter runs out of a rubber pipe at the back of the head & drips onto the undertray or the road. I think if the rubber pipe wasn't there it would just run down the back of the engine.
Symptom for the first one on mine was a strong smell of diesel in the cab whilst driving. Checking under the bonnet showed heavy vapour coming from under the plastic cover over the head & it wasn't until I removed that that the black death was visible - a lot of it too!
This can either be carefully chipped off or removed with thinners - which takes longer.
The injector can also be well stuck & it it won't come out when worked by hand DO NOT lever on the top of the head/rocker cover as the ally is VERY THIN. Using a spanner to twist can result in undoing the top of the injector.
I just refitted the clamp leaving the retaining bolt backed off a couple of turns to stop the injector being fired out & started the engine. Took a few goes on the worst one but it did the trick.
Alternatively get it done by a diesel specialist who should have the necessary tools.
A leak from the join of one of the metal feed pipes from the fuel rail to the injector will do much the same.
You need to inspect it all. Bear in mind you are working with very high pressures so take care.
It's all removable & is unlikely to cause any damage. Small pic in the link of 'black death'.
This is a particularly bad one on a Vito:
www.youtube.com/watch?v=n5BtcpzbseI
Unless the seat looks damaged there is no need to recut it. I cleaned mine up with wet&dry paper stuck on the end of a wooden dowel as suggested in the first link followed by hoovering with a tube that could go into the cylinder taped into the hoover crevice tool to clear as much as possible.
He's initially used far too much downward pressure on the cutter.
Heavy leak on a Santa Fe: https://www.youtube.com/watch?v=WNSrrXt7lag
Chap doing the injectors on a 2006 Tucson to 'God rest ye merry gentlemen' Hmmm.
If it's just the seal you don't need a new injector & he would do better nipping up the metal fuel pipe connectors to the rail & the injector BEFORE fully tightening the injector retaining screw. If the tube doesn't line up well it will leak & tightening it may damage the flare on the pipe so you'll need to buy a new one. Use another spanner to hold the union on the injector when undoing the pipe nut to stop the union unscrewing.
www.youtube.com/watch?v=XAZjEfFFOHQ
Try & locate the leak before you start any dismantling. Small torch & a mirror-on-a-stick are very useful for peering into nooks & crannies.
This type of thing: www.ebay.co.uk/bhp/inspection-mirror IIRC B&Q might keep them.
Not a fan of the rectangular ones with LEDs as I find the LEDs dazzle.
This is a particularly bad one on a Vito:
www.youtube.com/watch?v=n5BtcpzbseI
Unless the seat looks damaged there is no need to recut it. I cleaned mine up with wet&dry paper stuck on the end of a wooden dowel as suggested in the first link followed by hoovering with a tube that could go into the cylinder taped into the hoover crevice tool to clear as much as possible.
He's initially used far too much downward pressure on the cutter.
Heavy leak on a Santa Fe: https://www.youtube.com/watch?v=WNSrrXt7lag
Chap doing the injectors on a 2006 Tucson to 'God rest ye merry gentlemen' Hmmm.
If it's just the seal you don't need a new injector & he would do better nipping up the metal fuel pipe connectors to the rail & the injector BEFORE fully tightening the injector retaining screw. If the tube doesn't line up well it will leak & tightening it may damage the flare on the pipe so you'll need to buy a new one. Use another spanner to hold the union on the injector when undoing the pipe nut to stop the union unscrewing.
www.youtube.com/watch?v=XAZjEfFFOHQ
Try & locate the leak before you start any dismantling. Small torch & a mirror-on-a-stick are very useful for peering into nooks & crannies.
This type of thing: www.ebay.co.uk/bhp/inspection-mirror IIRC B&Q might keep them.
Not a fan of the rectangular ones with LEDs as I find the LEDs dazzle.
Edited by paintman on Wednesday 13th February 15:52
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