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W203 2.2d 2003 auto Fuel pump problem.

Discussion in 'Engine, Drivetrain, Fuel and Exhaust' started by Tilly, Sep 1, 2013.

  1. Tilly

    Tilly Senior Member

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    Need some help with a problem. Mrs Tilly came home stating she had nearly ran out of fuel. I topped up the tank with 10 litres of fuel from a jerry can. Got a call 15 minutes later saying she had broken down, and the management light had come on. Went out, and put another 10 litres of fuel in, just incase. The car would start, but if you revved it, it died, like fuel starvation. Let it idle for a few minutes, and I could get it to rev building it up slowly, without cutting out, but if you gave it some quick revs, it died of fuel starvation. Undid a high pressure nut slightly off the rail, and got good pressure of fuel squirting out. Decided to try and drive home, but as I drove it, it cut out several times, but restarted. After 2 miles, it died totally, again seems like fuel starvation. This time, it wouldnt start again. Took off the fuel line from the filter, and turned on the ignition. Fuel just came through in spurts, about every 3 seconds, instead of a nice flow. Decided to throw in the towel, and called out the RAC.

    RAC man did the same checks, disconnected the fuel filter, and tried to pull in some fuel with a hand bulb pump. He tried to tpull it through the filter, but it appeared to be blocked, restricting flow. Now, that filter hasnt been changed for 7 years, if that. RAC man bypassed the filter, but it still wouldnt fire. He used some easy start spray, and the engine was starting to kick on that, but no fuel was getting through. He decided the low pressure fuel pump wasnt pulling fuel from the tank, and the filter wasnt helping.

    e gave up and the car was towed to our nearest village garage, where it sits now, as there was no way he could tow it up to our house, due to the access.

    Anyone got ideas what the problem could be, as the local garage isnt going to have a STAR machine, and I guess they will tell me the problem is beyond their knowledge as a little business....

    Im going to get a new fuel filter as a matter of course....
     
  2. jj1975

    jj1975 Senior Member

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    Your Mercedes:
    w203 c220cdi 2002
    B4 you do anything fill fuel tank right up and try to start it battery may need help to get air out if it starts keep fuel tank over 1/2 full for few months Same problem I had with mine when run out of fuel .Car haz 2 seperet tanks conected because it haz complicated fuel pumps system when it runs out of fuel it need time to get air out till then the pump in a tank for levelling them will not work correctly .I'm not expert but with a bit of luck this may help you
     
    Last edited: Sep 1, 2013
  3. OP
    Tilly

    Tilly Senior Member

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    Easier said, than done. I cant make a petrol station. The RAC guy did try and pump fuel directly from the tank, with a hand pump.

    I will try and fill it up with a 20 ltr jerry can and give it a go, as I did read a few threads about the "saddle tank" issues...
     
  4. Steve@Avantgarde

    Steve@Avantgarde Forum Supporter Authorised Forum Supporter

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    Your Mercedes:
    C220CDI AMG Line Premium, SLR McLaren Roadster, SL55 & C32AMG
    Hand primer pumps and opening up the fuel system to crank wont do anything on CDIs other than increase the air thats in the system already and prevent the engine from starting. If the rail pressure is too low, the engine wont go and the minute you open up the fuel system you cause more issues.

    If you want to measure the fuel pressure you need a proper fuel pressure tester or STAR.

    First thing is first, what is the fuel gauge saying?
     
  5. OP
    Tilly

    Tilly Senior Member

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    Sorted. There was a quarter tank when it cut out. I had just put in 10 litres, as Mrs Tilly said it was in the reserve.

    Just went back to the garage, and filled the tank with 2x 20 litre jerry cans of diesel. Car started after a few cranks, and I've driven it home, without even a stutter. The management light is still on, but I have a code reader, so will have a look what it says.

    Thanks to JJ for the simple solution.

    What is the cause of this issue, and what should I be looking for to replace ?
     
  6. Steve@Avantgarde

    Steve@Avantgarde Forum Supporter Authorised Forum Supporter

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    High pressure pump most likely culprit. Common fault for them to fail and make the car run out at 1/4 tank
     
  7. star

    star Forum Supporter Authorised Forum Supporter

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    Smart + others :)
    Fuel filter Blocked???
     
  8. OP
    Tilly

    Tilly Senior Member

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    Fuel filter is the next thing.
     
  9. OP
    Tilly

    Tilly Senior Member

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    Took car out today for a quick run. 3/4 of a tank of fuel in.

    Noticed that if you tried to floor it, once the revs got high, it cut out from fuel starvation. Havent had time to put on a new filter, or look at the fault code, but its 100% a fuel issue.

    Will replace the fuel filter, and see what happens. Just hope Steve's wrong and its not the high pressure pump..
     
  10. jj1975

    jj1975 Senior Member

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    Your Mercedes:
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    Rev the engine and check 2 clear pipes under HP for air bubbles if u see them still air in fuel system or its getting in from somewhere it may be the filter too just keep fuel tank over 1/2 full till you sorted
     
  11. Steve@Avantgarde

    Steve@Avantgarde Forum Supporter Authorised Forum Supporter

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    C220CDI AMG Line Premium, SLR McLaren Roadster, SL55 & C32AMG
    If its cutting out on throttle then its losing fuel fuel pressure. When it cuts out does it say EPC visit workshop or Electronic Power Control Visit Workshop?

    If so its likely you have worn injector nozzles.
     
  12. OP
    Tilly

    Tilly Senior Member

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    It says nothing. Just the engine management light is on.

    Just replaced the fuel filter, bought from Merc this morning. Took it out for a 10 mile drive, and it seems to have solved the problem. Applying power from any speed no longer makes the engine cut out from fuel starvation, and it now pulls like a train, with the kickdown working ok. I will be cutting the filter in half to have a look inside.

    Chatting to the technical bod in Merc this morning, and he said the A class was renowned for grinding to a halt, from clogged fuel filters. Looks like this old 2003 C class had the same issue.

    Just need to find my code reader, and see what fault codes were brought up, and reset it.
     
    Last edited: Sep 4, 2013
  13. star

    star Forum Supporter Authorised Forum Supporter

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    When was it last changed?
     
  14. OP
    Tilly

    Tilly Senior Member

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    About 4 years ago. Mileage is about 180k
     
    Last edited: Sep 4, 2013
  15. star

    star Forum Supporter Authorised Forum Supporter

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    Age doesn't really matter, it's the amount of fuel that gone thru it, ie mileage when changed to now.
     
  16. OP
    Tilly

    Tilly Senior Member

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    About 40k miles, at least
     
  17. star

    star Forum Supporter Authorised Forum Supporter

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    I expect that's your problem.
     
  18. OP
    Tilly

    Tilly Senior Member

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    Cut the filter open today, and found the bottom had a strange yellow sludge. The filter looked clogged, so this was the cause of my problems.
     
  19. OP
    Tilly

    Tilly Senior Member

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    Thanks to everyone who chipped in a suggestion.

    Occums Razor: “All things being equal, the simplest answer is usually the correct one.”
     

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