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Fusion 1.4Tdi Starting - Needs To Be Primed If Left For Any Length Of Time


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My Fusie is becoming a nightmare!

This time, after leaving it for about 2 hours, it would not start (fired for only about 0.1 sec). Eventually after much cranking it started and ran fine. Got it back home no problem.

Next morning same problem.

Checked for leaks and smell of diesel but nothing found. No work carried out so nothing disturbed which might have caused this. Have checked lines and injectors under the air filter but no leaks or anything obvious there either.

Can only conclude that air is leaking into fuel system from the engine end causing fuel to run back to the tank . Priming hard for several seconds gets fuel back in the clear tube by the primer bulb and engine starts, runs ok, and will start again unless the vehicle is left for several hour such as overnight.

Any ideas?

Ta muchly.

David G, Fusion66

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I had exactly the same problem. Car would start with no problems if warm.

When left to rest for a couple of hours would not start. Priming for a minute or so would fix the problem, but this was particularly bad in winter when raining.

Took it to the garage, they replaced everything "cheap", i.e., filters, pipes, even the prime bulb. Problem was never solved.

Next would be the fuel pump or the injector. I took it an injector specialist and they fixed the problem (no issues for the last 6 months). Seems that the air "leak" was within the injectors. Not sure how they fixed it, it was not that expensive, but took them a week or so... they "explained" they had to let it rest overnight before testing... My guess is that some kind of seals within the injectors...

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Left standing in a Tesco car park on a rainy day there was a film of diesel fuel on the surface of a puddle when I returned. Not sure if this was my Fusie I moved it to another parking bay and left it for a few minutes. Sure enough - arrive in bay = no film, return after a few minutes = film. Checked for leak on fuel line and sure enough derv was dripping off the engine end just under the floor. This was confirmed by putting newspaper under the vehicle when returning home. It soon revealed /confirmed the problem.

Checking the Ford online parts catalogue ( http://eucatparts.com/?action=cat_ford )shows drawings with a steel pipe under the floor with plastic end pipes to tank and fuel filter.

The engine end is held in a multi clip with the return pipe and brake pipes. At this point the fuel pipe was dry but below was wet ....... A Leak! Probably a fracture due to engine vibration.

More info soon.

David G, Fusion66

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  • 3 weeks later...

Fault located to chafing of fuel pipe near the clips that hold the supply and return pipes and 2 brake pipes on the bulkhead.

Very difficult to repair - used 10mm bore reinforced hose - jubilee clip at filter end and bored out to 11.9mm at the steel pipe end and fixed with 2 small jubilee clips.

Ok - primed fuel line and it started first go

David G (F66)

Edited by fusion66
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