Interesting zed breakdown in the workshop this morning, was pre-booked as had some poor starting and running issues and a flashing a/t light at start up.

 

The owner made the good decision to stay over Friday night so we could see how it performed when cold, so I popped up to the local hotel armed with the ConZult and set about preparations before starting the engine.

 

So two codes were stored, afm and an 02 sensor heater wire fail, whilst looking at these codes with the ignition on I became aware of the very pungent smell of fuel! now I have seen the normal loose fuel lines hundreds of times but this was like been in a petrol station when they are having a delivery!

 

A quick look around did not really reveal the cause, but back to the afm and I could see on the ConZult the voltage was very high as if the engine was running at high revs! a quick attempt at starting was fruitless and the owner mentioned the normal 15+ mins it took to get it started.

 

So I changed the afm reset all of the codes and it fired up immediately, so back to the workshop quick smart!

 

Now the pictures will slowly reveal the real "cause and result" story behind this break down, the owner had been chasing the poor running and starting and had already spent money elsewhere looking for the issue and of course the failed afm had been missed but worse still to be revealed, as even with a replacement afm this was still an unhappy zed.

 

 

So the temp sensor had been changed and also no 1 injector on advise of the garage (?) the tps setting was way wrong the tick over was uncertain and the smell of fuel was incredible!

 

With the throttle cover removed the fuel smell source was revealed.....No 1 injector was spraying fuel sideways out in to the centre of the engine, this continued even with the engine not running!!

 

 

 

So knowing the injector had been replaced recently it was clear the "O" ring was having some kind of an issue keeping the fuel rail pressure under control and was going to need removal.

 

The accelerator cable and bracket need to be removed and at this point it was clear the cable was too tight and was holding the throttles open slightly, remember the odd tps setting from earlier??

 

 

So with the pressure released and the bits out of the way the injector was removed, fortunately this one is accessible with out any dremell work.

 

 

continue.....

Edited August 31, 201312 yr by JeffTT

So with the injector out the seal could be checked and the damage to it was clear...

 

Now the seal looked to be new but damaged so at first it appears it was badly fitted previously, however a further look into the fuel rail revealed the damage to the section the seal sits in!

 

 

Lucky a little work with a needle file got rid of the high sharp spots, this must of been caused by what looks like screw driver marks?? the seal never stood a chance!!

 

So now before fitting any injector always check its electrical integrity first, as sometime they can pop off for no reason..

 

 

So all good and the injector seals all lubed up and ready to fit...

 

 

The fuel was now all kept where it should be and ready to be checked over again but not before the filthy filters were replaced..

 

So now with the work above complete the throttles set the timing checked the base idle set this zed was purring like a kitten once more, oh the a/t flashing light was now sorted the dodgy tps setting was the cause of that.

 

The clues to the problems with this zed were all missed by the previous garage who had then gone on to make it worse...oh well all ended up good in the end.

 

Jeff TT

Edited August 31, 201312 yr by JeffTT

pics not working Jeff.....

On start up I get a flashing light, aswel actually. Power is the one illuminated, it's done it since I converted to manual I assumed that was the cause.

mine flashes as well approx. 10 times then goes off

pics not working jeff.....

 

fixed!!!

mine flashes as well approx. 10 times then goes off

 

Yup that's it

The yellow A/T or Power light flashing at start up is not an actual fault code but a warning that a code is stored in the auto ecu and needs retrieving, when doing a manual conversion the light will flash unless you un-plug the auto box ecu.

 

Jeff TT

I thought it was meant to do that

Ahh cheers jeff, any need to unplug that auto ecu other than this?

Ahh cheers jeff, any need to unplug that auto ecu other than this?

 

 

No need other than to stop the light.

 

Jeff

Thanks again Jeff for this thread. it gives me another reason not to go to a mechanic who doesn't know anything about Z's........