Fuel Tank (Aftermarket) Excel

[Tabatwa]

In November 2008 I purchased a new Isuzu 3.0 DEQ Double Cab 4x4. I decided to excahange the existing tank, capacity 76 L, for a larger tank, capacity 125 L. Camping & Outdoors (C&OD) recomended that I fit the Excel product made my Northern Offroad.

When they completed the job I noted the fuel warning light was on. I then proceeded to a nearby gas station and filled the tank up. The tank took 122 litres. I had no jerking or other problems associated with a near empty tank when I drove to the gas station, about 1,5 Km from C&OD.

About a week later and after travelling 400Km I noted the fuel guage was still reading FULL. I queried this. C&OD asked me to bring my vehicle in as they required to dismount the tank and check the installation. When I returned to collect my vehicle they advised me that the fuel guage was working but would indicate a full tank from the point where the original vehicle tank would be full ie 76 Litres, as the original Isuzu fuel guage had been installed into the Excel tank. According to C&OD Excel does not supply a guage for their aftermarket product, and therefore there is no guage specific to the 125 Litre tank. One has to rely on calculations to ascertain wht fuel is left in the tank before the indicatior starts working when you have 76 Litres left.

I was certainly not happy about this and if I had been informed before making the purchase the would have certainly made me consider other alternatives.

I have continued using the tank for the past few weeks and have found that by monitoring the fuel consumption meter (now standard on the new Isuzu DEQ Double Cab) I can reasonably accurately calculate what fuel remains in the tank. For example if the trip indicates 345 km and the L/100 km indicates 12,5 i can calculate how much I have used ie 3,45 x 12,5 = 43,125 Litres.

Now for the real problem. Yesterday on the way home from work my vehicle "ran out of fuel" even though the guage indicated that it was 1/4 full and according to the above method of monitoring the balance I had 20 litres in the tank.

As the engine management light came on when the vehicle cut out and the guage indiacted that I had 1/4 tank I assumed I had some sort of fuel pump problem and immedietly summoned the Isuzu Service Manager at South Coast Motors, Amanzimtoti for assistance.

The Isuzu crew duly arrived and connected their analysis equipment to my vehicle. The analysis machine indicated a fuel pressure problem in the fuel line. The mechanic immedietly tried to bleed the system. No fuel wasbeing pumped down the line.

Even though the fuel guage indicated there was fuel in the tank the mechanic had doubts and recomended we proceed to a nearby garage and purchase diesel. We managed to get a 5 litre container and filled this with diesel. Thereafter we poured this into the tank and commenced bleeding the line. Fuel was soon flowing and the vehicle started.

With the mechanics supporting me in case of another breakdown we proceeded to the nearest gas station about 2,5 km away. I filled up the tank. It took 101 litres. Together with the 5 litres added this meant we had added a total of 106 litres and 19 litres remained in the tank.

My calculations ie data from the trip meter against average consumption tallied with this.

When my vehicle ran out of fuel 19 to 20 litres of diesel remained in the tank. The fuel guage indicated 1/4 full.

What has gone wrong? Why when I first collected the vehicle when only 3 litres remained in the tank did it draw fuel from the tank without the problem. Now when 20 litres remains it will not drwa?

My surmisation is that the float is floating in the 20 litres in the tank correctly indicating the remaining quantity, but somehow the intake feeding the fuel from the tank is sitting at about the 20 litre level and as soon as the 20 litre mark has been passed the fuel pump sucks in air and not fuel casing the fuel run out issue.

I am hoping that the fitter at Camping and Outdoors is responsible and has not fitted the fuel pump correctly. If it is a defective/inadequate product I can see a battle looming ahead between myself Camping and Outdoors and Northern Offroad/Excel.

I would appreciate input from Forum Members who eithet have had similar problems or who can prpopose a solution. My first prize is to get the Excel tank working. However, I cannot risk the same thing happening to me in Moremi.

One last comment. It is about time that in South Africa we had some sort of accrediation system for Manufacturers of offroad accessories and the fitment centres. People could lose their lives because of incompetence and that should be taken very seriously.

[Christo Davids]

Just a thought:

Was the vehicle parked uphill / downhill when you ran out of fuel? Maybe the tank is regtangular and when parked level, the fuel covers thr bottom and the outlet, but when on a steep uphill / downhill, with the outlet on the front / back, there would be fuel in the tank, but the fuel would not cover the outlet of the tank, creating an airlock

I don't know whether this is possible, but I think it is worth investigating, otherwise it sounds very strange

[Tabatwa]

I was driving on a perfectly flat road. The Southern Freeway from Durban to Durban (Louis Botha) Airport.

I have taken the liberty of contacting a few installers and they are very surprised. All of them say that Excel is the best tank and that Excel give very clear installation instructions. I have a strong suspicion that Camping & Outdoors Technician fell asleep.....

[Tabatwa]

I have just come off the phone.

Guy by the name of Chris at 4x4 Megaworld seems to know his stuff. He is very pro the Excel 125 Litre tank. He says when installing the sender unit it has to be done very carefully otherwise the float will brush against one of the plates inside the tank and cause all sorts of problems.

He confirms the fuel guage will register as full for a long while before it goes down to the full level of the original unit. He also says the low fuel warning light comes on while there is pleanty of fuel in the tank. (The previous Isuzu D-Max certainly had the light come on when 15 L remained).

Tony and Mark owners of Outdoors & Camping have assured me they will fix the problem.

Hopefully I can give the happy ending in a week or so and hopefully the lessons learned here can save other Forum Memebers from similar problems.

Lessons learned:

1. Make sure the product you buy is respected and get opinions first;
2. Make sure the Installer is respected and has done previous installations on the same product. Avoid being the guinea pig.

[Henris]

I don't believe my fuel guage. I believe in my trip counter.

Under heavy load, 1,400km(with loaded car trailer +-2,000kg). Just cruising with the RTT and fully kitted, no trailer, 1600km. The fuel guage I use as a vague guide.

[Gatecrasher]

My supposedly 140L excel tank is coming out for the 4th time for repair on Monday after springing a leak again ! This is not a cheap exercise ! I love my Patrol and the biggest problem with it, is it's thirst. One has to live with that if you love the brute. But not with it leaking petrol as well ! Each removal and repair costs about a Grand !