3SGE Gen III cold start/fuel issue

**Andrew162** · 01-03-2011, 03:11 AM

Lads I've been having a bit of an on-going issue with my engine after 2.5yrs of faithful service it's only now had it's first problem.

This started late last year/early this year when school hol's were on and I had very little need to run my car. So little need that I had it in the garage unstarted for about 3 weeks. I kick it over one day and it splutters under first kick high-idle. Eventually it got up to 2k rpm (where it normally shoots straight up to when kicking over cold), but thenafter I noticed a strong fuel smell. There was a minor leak from source-unknown, but was still idling ok, settling into warm idle, all's good, take it for a blast down the Hwy, no issues and no fuel smell either.

A couple of weeks later Steve (wagonist) comes up for a visit and I point this issue out to him while he's there. This time I hadn't started it in only about a week, and when I kicked it over it pissed out about a litre of fuel from what we guessed was the back of the engine bay. We both got our heads in under the bonnet and couldn't really trace where the leak was coming from. Again, it settled into warm idle fine after piddling on the floor, eventually the leak stopped after about 5 minutes. Both Steve and I were scratching our heads at this one.

Since that time it hasn't leaked any fuel at all, but after a few days unstarted it does present the same spluttery cold start symptoms, if only briefly (maybe a second or two). It still drives fine, no issues with fuel delivery that I can see/notice while driving...

So I'm a bit stumped on this one, but I do have a hunch that it could be a perished/leaky hose somewhere that I can't access. I'm definitely thinking first kick/cold-idle fuel pressure. Originally I thought it was fuel return but I'm still not 100% on it. The GenIII doesn't have a cold-start injector so that's ruled out. I am open to suggestions, whatever you think it could be please post.

Sorry for the long thread-starter but I wanted to be as clear as possible before I got too many questions about symptoms rather than answers.

Thanks for any help.

**Andrew162** · 04-03-2011, 02:20 PM

Hrmm, no one knows...

**Dale** · 04-03-2011, 06:48 PM

The most likely things that it could be:

1. banjo fitting from fuel rail to fuel filter - either at the fuel filter end or the fuel rail end
2. bottom fitting line into fuel filter (HP line from the tank)
3. return line from fuel rail (LP)

with 1. - there needs to be a copper washer top and bottom of the banjo fitting
with 3. - these are normally sealed with a flare on the hard line and a clamp - clamps could have moved/come loose or the hose is damaged

Both of these will leak towards the gearbox end of the engine. Injectors would probably just leak into a cylinder rather than onto the ground so it's unlikely to be that.

My bet would be on the banjo fittings either not being tight enough or missing a washer (possibly both). When the engine gets a little heat the gap closes.