AkCustomz

iTrader: (2)

I know this isnt a scooby but im stuck working on my dads 04 sante fe crtd 2ltr turbo diesel.

Problems started with the jeep cutting out randomly but more noticble on kick down. When it would cut out it would be hard to start it right away. You could hear that the fuel pump wasnt kicking in so we just kept turning the key on and off till we heard the pump on again then it would start.
But recentley it got a lot worse. My dad was driving it back one day from work and it cut out 30-35times in the space of a 40mile drive! When he got it home i could hear clicking when he rev'd up the engine that seemed to have matched engine speed.
I thought it was injectors so hooked up a flow test kit but all injectors were running evenily. This is the only testing ive done so far beside check oil and that was above min. Topped it it and still the same.

Can so help? Or am i being really stupid and missed something obvious? Which wouldn't be a supprise to me lol.

DT-SPD

iTrader: (7)

Have you checked for any fault codes ?

AkCustomz

iTrader: (2)

I was hoping someone might have experienced something like this so i could attempt to repair myself. As we will have to fork out on recovery then main dealer charges for diagnostics. I tried my obd reader but hyundai have made it impossible for none hyundai code readers to check for fault codes for anything upto 06reg on the diesel side.

merlin24

iTrader: (1)

Have you checked the basics :
Air filter clogged ?
Fuel Filter Clogged ?
Induction hose collapsed ?

Mick

scottydog137

iTrader: (2)

Is this a commmon rail diesel engine?

AkCustomz

iTrader: (2)

Yeah forgot to mention them mick but the all good.

Yeah it is scotty

scottydog137

iTrader: (2)

As you mentioned it is worse under kick down i take it as being automatic!!,

It could be a problem with the fuel line return valve or the fuel rail pressure switch!!

AkCustomz

iTrader: (2)

Yeah it is an auto.

When i hooked up the injector flow test kit the fuel return lines that come off was constantly pumping out diesel about the same rate as what the injectors were filling tge cups out. Is that normal or could this be a sign of a problem. Also where abouts would i find the pressure switch?

360ste

iTrader: (1)

The fuel return line should not be pumping fuel out. Try taking the fuel cap off to see if this improves matters. But only do it with less than half a tank or you could spill fuel and risk getting pulled over. I say this as unless there has been work on the fuel system recently I can only think of a blocked breather allowing the tank to pressurise to cause the fuel to come out of the return line.

DT-SPD

iTrader: (7)

Fuel from the return liine is normal, its usually spill from the injectors and the return from the high pressure pump.

You mention about the fuel pump not cutting in, if you mean the electric supply pump from the tank to the high pressure pump then that would cause stalling as if there is not enough fuel supplied to the HP pump it can not make enough pressure and the engine will shut down. Only doing it at kickdown could indicate a failing supply pump that can not deliver enough fuel under high demand ??

lookout

I have seen these with cutting out problems around 20K miles on them due to fuel filter being clogged. Normally starts with cutting out at high revs/load. Common occurence.

AkCustomz

iTrader: (2)

When the cutting out started months ago i did a service on the jeep including filter change and i even swapped over the in take fuel pump. It seemed to have fixed it for a while but got worse recently and now has developed the click/knock when the engine is rev'd up. Its not bottom end sounds like its coming from the top and listened to it again today and seems to be an equal gap between each click/knock. I will try get a sound clip loaded up later.