Well everybody. Its a 90 mk 4 efi xr3i.Car just died the other evening. Thought it had run out of petrol but it didnt shudder or kick like it was about to run out. It just died on a roundabout of all places. Put some petrol in it but nothing. Started at one point but wouldn't rev and has been making attempts to start ever since but wont fire at all. Ive got fuel coming to the engine. The pump is energising as it should. I've got spark on all the plugs. It had a new fuel filter fitted about a month ago. I had a spare distributor and leads and put them on but didn't change anything. The breather pipes are clear and i cant see any cracks or obvious holes in the air intake. The pump has been running louder recently if that helps.Im quite puzzled. Any ideas where to look next? Thanks a lot.

 

I've tried changing the cps, ignition control module and a sensor stuck to the bulkhead all of which made no difference. The car started briefly but wouldnt rev properly and cut out. It was also doing this when it broke down. Its probably only started about 3 times since it broke down but cuts out almost immediately and doesn't really rev.

 

Sounds like the fuel damper that goes between the pump and the metal fuel outlet/feed on the tank, had exactly the same problem with my 2i.

How much fuel is actually coming out of the fuel return on the rail?! From memory mine had hardly any due to the system not pressuring properly due to the splits in the seals. If it is that you can replace it but know some people just take it off and fit a fuel hose instead!!!

 

This is the xr2i one, I'm guessing should be the same /similar on an efi 3i!!

 

How much fuel should be coming out? I havent got anything to check pressure. I only checked at the inlet to the fuel rail and turned on the ignition. A healthy looking amount came out but i didn't measure it. I had the pump out recently enough chasing another problem and i dont recall there being a damper on it. The way things are looking though its possibly a pump problem of some sort so im gonna have to drop the tank again. I can have a look at the damper then.

 

Well with mine there wasn't a lot returning to the tank due to lack of pressure. Another thing to try before you drop the tank is take the cross over pipe off and spray easy start or carb cleaner in the inlet, if it picks up and tries to run you know it's a fueling issue.
May not be that but very similar to my 2i, I didn't notice it was the damper till I noticed a split on the seal one end!!

 

as above try spraying some easy start into the air intake if it fires up breifly until the easystart is burnt off , its more than likly a fueling problem

 

I sprayed some carb cleaner in the inlet(its all i had) and the car started and revved right up to 6000rpm as it should. Is it safe to say i should drop the tank and have a look? Pumps lost pressure by the looks of it.

 

So i dropped the tank and took out the pump. The damper is on it but there is no visible damage to the seals or clips. Took it apart and it's like new. It also fits really tight onto the pump and opposite inlet pipe so i'm not convinced thats the problem in this case. I'm wondering now is it dirt in the fuel system somewhere like the injectors. Also does anyone know how to test the pump on this car in terms of fuel output per minute or something like that?? Just so i can determine if the pump is actually ok. I didnt have the gear to do a pressure test so this is my next best bet. Thanks again for all the help.

 

Did you check how much fuel was coming back out of the fuel return?! Best bet is to take off the return pipe and put a bottle or jar in its place then crank it and see how much/how fast it returns to the tank

 

Also my damper seemed ok and tight till I took it off and pulled the seal off, then I noticed it had a small split down one side!! You could try taking it off and fitting a fuel hose instead with some jubilee clips. Would have thought unless all injectors are down it would still run just rough as!!

 

try to bypass the damper or chuck in a known good pump

 

well lads. I just put a brand new fuel pump in the car and just finished working on it now. Started first turn and is driving so much better than it has in recent months. Problem solved. Thanks for all the help.