ZD30DD diesel pump

[RENATO FERNANDEZ]

Hi all, I have a serious issue and I require some assistance. I was driving along the highway and my vehicle's "CHECK ENGINE" light came on suddenly (no signs of overheating, RPM change etc.) then the engine died on me and the ignition lights came on. The engine tumbled fine but refused to start so I had to have the vehicle towed to my house and I got an electrician to run a diagnostic scan on it and a '"DIESEL PUMP ERROR" code came up. I was afterwards told that the sensor cannot be replaced or repaired and the entire pump has to be replaced. I am located in the West Indies and my mechanic is telling me that this can cost as much as US$1800.00!! That's a ton load of money to put out for an individual living in a small island in the throes of a DEEP recession. Are there any wizards out there who can confirm that the pump definitely has to be replaced or can this sensor be changed or repaired? Begging for some assistance or feedback please!!!

[Rumcajs]

G'day,

The ZD30 pumps VP44 from Bosch/Zexel are expensive to fix and repair and made deliberately that way. Welcome to the scores of owners who have been cheated this way.

If the engine has shut down chances are the injection pump kaput.

These pumps are terrible and most parts in them are replace only. That's why clean fuel and regular attention to injection system are crucial to avoid this fate.

I'm sorry but there is no other way out of it your mechanic is right.

Regards

 

[RENATO FERNANDEZ]

I've only had one diagnostic scan run and the electrician wants to run another with a different scanner so how can I confirm that it's definitely the pump? The engine tumbles fine but doesn't start and the "CHECK ENGINE" light stays on. I was wondering if I slackened one of  the injector lines and tumbled the engine and there was no diesel spray that would confirm it. If there is diesel going to the injectors, what else could be the issue? I am prepared for the worst. Our fuel quality is pitiful in the island although we are a petroleum rich country. Anything else I should look forward to from this engine??

https://www.ebay.com/p/Bosch-Injection-Pump-0445010136-0445010158-0445010159-for-Nissan-3-0d/566436477?iid=222739372120

Is this the culprit that is causing me all this headache?

[Rumcajs]

Well,

I'm assuming your engine has what is termed as radial injection pump which is not common rail system. What year is your vehicle?

The link to E-bay is for common rail injection system.

Is this how your engine looks like ==>

[RENATO FERNANDEZ]

The vehicle is a Nissan Caravan E25 panel van and I think it's 2006 and I purchased it second hand 4 1/2 years ago. No major problems really but had a big scare a year and a half ago with a cracked cylinder head gasket. I ended up on this forum because of a Google search and I believe the engine is the same. Because the engine is hard to access, I am not sure if it's the identical engine to the picture you posted. Sorry.

[Rumcajs]

You will need to clarify which version of the ZD30 engine fuel injection is in yours.

There are two types with completely different systems and different operation so giving you any advice is conditional upon that clarification.

Regards

[RENATO FERNANDEZ]

ZD30DD.pdf

This is from a service manual I purchased online. This is the engine in question. Your picture look a little different.

 

Edited January 16, 2019 by RENATO FERNANDEZ

[Rumcajs]

Ok,

Yours what I suspected, conventional mechanical diesel injection system. Injection pump is Zexel/Bosch VP44 radial pump and what I posted earlier applies. Dreadfull  device it is.

The link you posted to Ebay is not applicable to your car then.

Your mechanic will need to connect special scanner from Bosch directly to pump ECU to read/diagnose the codes which will narrow it down but prognosis is not good.

These pumps have fatal flaws and will fail suddenly and without any warnings. If one of the sensors fails for example the entire assembly of sensors and actuators will need to be replaced. Most common failure is actually that inbuilt ECU where its internal circutry is subject to failure due to mostly overheating cause either fuel supply is restricted/compromised.

Search "Bosch VP44" isuess your will see....

Those things are ticking time bombs.....

Regards

 

[Rumcajs]

Having said all that, checking if all electrical connections to the pump and grounds are good first would be a good start. 

 

[RENATO FERNANDEZ]

Hi Rumcajs, thanks for all your input. I'm prepared for the worst scenario now that you've explained everything in detail. One other thing, in the event that the Gods have smiled on me and it's not the pump but a simple electrical issue, what precautions can I take to prevent this from happening again? Can these pumps be serviced by a qualified technician to keep them operational despite the quality of fuel I have to deal with locally?

[Rumcajs]

G'day,

The only servicing required is good quality fuel and regular fuel filter replacement (more often then service intervals from Nissan due to poor quality fuel).

Some people try additives in the fuel like diesel treatment types ( I'm not sure what is available in your area) which can be helpfull when quality of diesel is low.

I use here in Australia Chemtec Diesel Power

I also add two stroke mineral oil in ratio 1:200 (or multiply liters of fuel added to tank by 5 to get the amount of oil to ad in ml)  because older Diesel fuel injection system don't handle low sulphur diesel fuel that well so extra lubricity doesn't hurt. As for legality of that thats another matter.

So in your case finding additive for low quality/ bad fuel could perhaps be beneficial.  There is also a modification to add external electrical fuel lift pump to ensure fuel starvation will never occur because that is one of the main killers of those pumps but there is a modification needed to be done to spill/ injector leak off  pipe otherwise the engine will be pumped full of fuel. This apply to Nissan Patrol so I'm not sure how is fuel return from injectors leak off or spill line routed in your vehicle. External lift pump like Carter 4600 series or Walbro 13-2 or better abble to supply up to 12 psi head pressure will improive things greatly but it does require you to understand thing or two about fuel supply on ZD30 and routing of fuel lines/

The injector pump has its own lift  supply pump built in but it is hopelessly inadequate especialy at low RPM so bonus is when fitting external supply pump is a slight gain in low down RPM power increase.  In that case injectors spill lines is connected straight to suction side of the pump port which means it needs to be connected changed to return line to fuel tank.

Regards

 

 

Edited January 18, 2019 by Rumcajs

[trevzd30]

While it is probably your injector pump like previously said, I had a similar experience with my zd30 many years ago which turned out to be a faulty crank angle sensor. Once replaced it sprung back into life.

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[RENATO FERNANDEZ]

Well, the problem turned out to be the pump and I dropped the van off at a recommended reliable diesel mechanic (remember, small island in the West Indies!!). He said it's a common issue with this vehicle and others that carry the same pump and the major culprit is poor quality fuel (I was told by a friend working in the island's petroleum distribution company that we do not receive or refine "Diesel" as such. He says we are supplied with GAS OIL, not white diesel). The mechanic had at least 3 Mitsubishi L300 vans, along with Nissan Frontiers and a couple more Caravans so it's not me alone with this suffering. I did some checking on the forum about the Carter 4600 pump and I think that I understand fully what it actually does, providing an ample supply of pressurized fuel to the diesel pump so that the diesel pump itself is not under strain to pull fuel all the way from the tank so I'll look into that. Problem is, with the tight spaces, will I find room to install this lift pump inside the tight confines of this panel van? Other questions...(Please be gentle. I have 0 knowledge of the build of this engine) 1/. Is this lift pump installed after the fuel filter? I would assume "YES" to avoid additional strain on the diesel pump to pull fuel through the filter. 2/. What is the purpose of the spill/injector leak pipe? Does this allow excess fuel sent to the injectors to flow back to the tank?

[Rumcajs]

Sorry to hear about that.

To answer your questions:

1. No the extra lift pump will be/should be installed before the fuel filter cause they're better to "push" the fuel than pull, it that is their primary design.....

2. Yes spill/leak off pipe returns excess fuel back to fuel tank or back to suction side of the IP side, depends on the  design chosen.

Nissan Patrol ZD30 implementation is to return the spill line to the suction side of the IP pump cause inbuilt vane lift pump( which is itself dreadful design cause it requires higher RPM to increase the flow rate) Thats why We have to re- route it to return to overflow side of IP  fuel return line when using external lift pump to pressurize what was suction line which would ruin the spill line workings. The good old design is to return spill line to fuel tank, it improves fuel cooling as well, unless you are in Arctics or similar very  environments where it will help heating/warming of the fuel. In hot climates it is a disaster to have.

Some designs out there have thermostatic valve which depending on ambient temps re-routes fuel flow from spill line either back to fuel tank (hot day)or back to fuel filter suction line(cold day). Sadly not on Ni$$ans LOL.

Be vary that Carter 4600/4601 lift pumps installations require to have as a safety measure bypass built in in case of the pump failure or blockage  as fuel starvation will result in IP failure again.

Regards

[LongiE]

Hi Runcajs.

Just reading your stuff on the IP. It is really informative. I am looking at a 2002 Patrol GU and the only thing that makes me hesitate, is the terrible IP reputation and the cost to fix it. The car i have been looking at is owned by and old mechanic you changed the oil , oil and fuel filters every 5000km and always used fuel injector cleaner (and kept record of doing so). would his extra care shown possibly extend the life of the pump. This car has done 25000km and my mechanic say he does a lot of patrol (pre common rail) IP's at around 30000km. His opinion is don't do near it i'd appreciated your opinion. If you think it could be OK should I go ahead with the lift pump mod you suggest.  Thanks again great advice

[Rumcajs]

My honest answer is consistently the same. I do not recommend to buy! Not that vintage anyway unless you have replacement motor handy or enough funds to spend when inevitable happens. Or plan a coversion to different engine like TD42, LS2, Cummins or whatever else people spend their money on.

Servicing that engine makes no difference, it is terrible design done when Nissan was nearly bankrupt (it should!). Bosch is another swine of automotive dregs!

Either way if you are not handy with spanners or want spent weekend under the bonnet keep away from that abomination unless you have a lot of cash to burn.

Look it is terrible car on the road, under powered and ready to expire at moments notice. It is only good in low range doing 30 km/h, then it goes anywhere.

I know it sound harsh but that is the reality of owning Japanese 4WD. Their endless issues with everything while costing a fortune to drive is the norm.

Regards

 

[LongiE]

Cheers totally understand your point of view. I'm handy with the spanner but not desperate.

[gcpbuddy]

It's definitely a pump problem . Throw it out by a new one . They are also a pain to fit . Make sure your engine bay is clean before you install one


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[AutoClubMan]

I installed a pump from a truck with a ZD30 engine and a separate pulley, I made a new pulley with a smaller diameter and increased the pump performance