FUEL pressure problems... P7 code

Hi all.....
My 05 Nissan Navara 3.0lt Turbo Diesel D22 (ZD30 DDT, 98,000kms) has major issues with the Fuel system... The engine light has come on "water in fuel', I have changed the filter (fair bit of sediment in filter) twice and no luck probs still there and engine is in limp mode...
This has happened once before at 30,000kms and it was the o-ring missing on fuel filter spigot that was causing probs, I fitted one and no issues til now (Have changed fuel filter every 5,000kms but not o-ring)...

I replaced fuel filter again last night. I have fitted a clear line from filter to line going to injector pump.... AIR BUBBLES!!!!! I put the clear hose straight into a fresh drum of diesel no more air bubbles but prob still there... ARGHHHHH!!!!

Obvious things I have done...
1 - New fuel filters,
2- Bypassing fuel lines and using a clear line straight from a fresh drum of diesel into the injector pump line... No air bubbles into the system anymore but the car still in limp mode, runs rough and blows lots of smoke...
3 - I cleaned the earth points (there was a bigger one next to the three smaller ones so I did all four.... Still running rough and blowing smoke. Does the computer need to be reset to make it run properly ????
If so how do reset it???
4 - I checked the piping going from the turbo to the Manifold a little oil in there but not HEAPS, same when I removed the Air Filter boot and hose and looked down the front of the Turbo...
5 - Air Diaphragm..... - Dunno have to wait til 2morro.

6 -Turbo Outlet tube - I'll check....

7 - Compression test.... Don't have the equipment....

8 - Turbo - It was still performing on the way home when the light first came on but it's gotten a little worse and lost some power now....

Nissan claims the issue is the injector pump due to the I-7 code that is coming up from the engine warning light coming on... I hoping NOT as they quoted $3500....

questions:
1 - Could it be the injectors blocked if I've have dirty fuel???
2 - I have another filter (Ryco Z332) ready to go on and I'll go and get a new O-ring for the filter spigot too....
3 - Should I get the injectors cleaned???
4 - Is there anyone in Newcastle that could do the job cheaper PLEASE HELP!!!!!!!!!!!!
5 - Is there anything else I can do???
6- Does anyone know a reputable diesel specialist in Newcastle????
7 - I have a 130 lt long range tank,... should I try to flush it somehow???

The smoke is black sooty looking on start the a light grey/blue I suppose on revving at 1500 - 2000rpm.. Hard to tell.. Smell - Like a stinky old diesel. LOL


Thanking you all in advance,,, I know it's a long post but I had to get it all out

You might have got a bad batch of diesel.

Was there a lot of water in the separator??

From my experience the P7 code means (unless you have got it early) you have done damage to your injection pump.

The P7 cone normally comes up after you have had a bad batch of diesel eg, with a heavy dose of water in it or just poor quality.

What happens is the pump uses the diesel as a lubricant and as soon as water gets in its no longer gtting lubricated and scores the inside of the pump and therefore there is a larger space in the pump which equals a lower pressure, which then means its in limp mode as itsisnt getting the pressure required to the injectors.

my suggestion is if you have a large drum or something, drain your tank ( lucky you have an aftermarket tank as the genuine one doesnt have a drain bung) check out the quality of the fuel, blow the lines clean from the pump back to the tank. and replace the fuel filter with a genuine nissan unit.

Then if that Fails more than likely you will need a pump overhaul and that isnt going to be too cheap as they are an electronic pump and the electronics have a tendency to rust up and fail.

There is a company on the central coast called Shepards Diesel i think the guys name is Neil, thats where we used to send all our injection pumps for repair and he is a licenced denso pump repairer. His pricing is very resonable but its hard to quote on a pump with out pulling it a part as you dont know what damage has been done.

Hope this helps.

Cheers

Buddhi

bradk said:

.......
This has happened once before at 30,000kms and it was the o-ring missing on fuel filter spigot that was causing probs, I fitted one and no issues til now (Have changed fuel filter every 5,000kms but not o-ring)...

Click to expand...

i think buddhi has already said most of it.

ECU i think you can reset by unplugging battery and leaving off for a while.

now the o-ring is an interesting thing. recent discussing on it with local mech. apparently that o ring all depends on th filter you use. a lot of filters have an o ring inside the filter around the internal thread. therefore they do not need one on the spigot.
however some filter do not have that o ring built in so they have one supplied in the box with it.

i would leave fuel in that tank for the time being. get a sample and get it tested. if its out of spec (most likely due to the water) there is a chance you may be able to get the gas companies to pay for the repairs. i understand a fair few car companies and insurance companies have had payouts from fuel companies due to substandard fuel.

i understand that with these fuel pumps if you run it with high fuel inlet restriction (blocked filter) the seal between high pressure and low pressure area gets ruptured and the pump is basically toast.

also if it sucks a lot of air the air bubble stops the fuel from cooling the ECU on top of the pump, again dead pump.

only good news is it cheaper to fix than a common rail system

Ryco filters are shite, use Nissan fuel filter's. Dont go cheap on a diesel fuel system. Everything costs a fortune to replace or rebuild. Use quality parts.

Dave.

I agree with Dave, get a genuine Nissan fuel filter, the Ryco ones don't seal properly because of poor gasket design, but I don't think it will help, if you've fed it direct from a jerry can and there is no air getting into the injector pump and it still is blowing smoke and running rough you've either got a pump problem or an injector stuck open, either of which will need a pro to look at.

Thanks guys.... Sorry for getting back late.....

The beast is in at a Diesel Specialist (Craig Palmer) in Mayfield West....New pump being fitted.....

Lucky it went in too...... Low and behold another problem..... The starter motor was loose and about to fall off !!!!, Looks like when Nissan replaced the gearbox they didn't tighten the bolts properly and wah lah.... The starter was throwing itself away from the bell housing etc at the same time it was trying to engage, arcing and sparking going on too..... Hopefully the bolt holes etc are too damaged......
Dunno about the injectors yet, should be ok (touch wood)

Will let you know

Oh on a side note what's the EGR/butterfly mod

not sure about useing genuine. the filter that cloggd up on me was genuine. while it had a bit of what looked like rusty water caught in the trap, the filter material had been sucked in the outlet holes.

i have a couple of different filters fitted on the utes at the mo with no problems.

egr/buttefly mod... http://www.navara.asia/general-tech-talk/64-egr-butterfly-mod.html

I have had problems with non genuine as well, pin hole in side near seal, dodgy manufacturing caused motor to stop dead, NRMA couldn't start, had to be towed to Nissan, a $30 filter who'd think ?