1999 XJ 2.5TD stopping when going uphill with under half tank

[EtronX]

Greetings from Norway

Recently I bought 1600 kg of hobby. A nice and rustfree Cherokee with only 119.000 km on the dial. All fluids on the car have been changed, as has the diesel filter. There is a small leak in injector #1, but that will be sorted soon.

I have one problem that I have pondered on a lot lately. When going uphill with less than half tank the engine stops. Basically it runs out of fuel. Then I have to pump and bleed the diesel filter for it to start again. The same hill with full tank is no problem. I have narrowed this down to the fuel transmitter assy in the tank. I guess it is supposed to hold a certain amount of fuel so that fuel will be delivered to the engine when going uphill and/or on winding roads. In these cases i guess the fuel is at one of the sides in the tank, and not at the pickup point. My latest epiphany is that the fuel pickup assembly is leaking internally, and therefore holds no "reserve" fuel for the uphill/winding roads.

Has anyone taken this assembly apart and rebuilt it? Is that possible for a guy with two thumbs and a lot of carrots for hands? Does my string of thoughts make sense?

Stay safe in these strange times.

[layback40]

Are you sure the supply & return lines have not been swapped? This will cause fuel starvation when below 1/2.

[EtronX]

Originally Posted by layback40

Are you sure the supply & return lines have not been swapped? This will cause fuel starvation when below 1/2.

Thanks a lot for the reply. I’ll check today, but then the next question is which of the two outlets on the fuel assembly is the sypply line?

[amlav]

Also can be something to do with the pick up in the fuel tank .
Fuel supply hose can be identified if blowing a bit of mouth full of air in the hoses . When blowing in the supply hose you should hear like a bubbling sound coming from the tank ( if tank is full).

[EtronX]

Looks like the pipe with the blue clip is the feeder line. Then everything is correct on the car. Then I guess the problem is in the whole fuel supply module. Time to take it apart.


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[layback40]

Originally Posted by EtronX

Thanks a lot for the reply. I’ll check today, but then the next question is which of the two outlets on the fuel assembly is the sypply line?

If you have the fuel tank low, say below 1/4 & you remove the filler cap, you will be able to blow air through the return line without it bubbling in the tank.
If your problem is a blocked strainer screen in the tank. It can be cleared by using a compressor to blow air back down the filler line. I have even done this at a fuel station using their tyre air when I had bad fuel.

[EtronX]

Thanks [emoji1303] I’ll try that.