Fuel Issues

[Bob R1]

2024 Roxor, 2.7L, 5 Speed, Bone Stock Engine, no tuning of deletes so far.

To start with I was having to crank longer to start once in a while, not every time. Then this got to every start I would need to crank waaaay longer than normal to get started. The last two or three times I have driven it, it took a very long crank to start every time. Doing a quick restart after shutting it off still took a long crank to start. On the way home this afternoon the check engine light came on. No obvious loss of power has been observed.

Any ideas?? Fuel Pump/Lift Pump quit?? Fuel Filter?? Something else??

First Fuel Filter Change 8/04/2025 3970 Miles
8/27/2026 Current Miles on Roxor 7499
So 3,529 miles since the fuel filter plugged up the last time. Pretty close to the same amount of miles as the last time I had to do a filter change.

Anyone run a John Deere RE533026 Fuel Filter? My last filter from Mahindra was $85 and did not come with the water sensor. Going to West Planes Missouri next Wednesday, so I can check at John Deere as well as Mahindra. I will probably do a Fuel Filter Change even if that is not the problem.

Bob R

 

[USMC]

Hello Bob,

Sad to hear the issues. I posted this earlier for another individual: Well, you are down to a working fuel supply, proper compression, and a functional starter system then. That is all that is needed for the Roxor to fire.

 

[Bob R1]

It is cranking fine, it just acts like it is not getting fuel in a timely manner.
Throwing the engine code has me a little concerned that it might be something besides a fuel filter. I read something that said a 2.7 did not have a Transfer Pump in the fuel tank. I find this hard to believe. It really acts to me like it is not getting fuel to the injector pump.

Bob R

 

[USMC]

Type this in the search box for the 23 and up Manual,

Free 2023 & 2024 Roxor Repair Service Manual​

Your info on the fuel system starts on page 267.

WM435 posted the newer manual.

 

[WiredOwl]

I’d pull the check engine code before throwing any parts at it. With the fuel filter plugging once already and almost the same mileage on this one, changing it again makes sense as a first step.


If it turns out to be clogged again though, I’d be looking a little deeper at the fuel supply rather than just treating the filter as the problem. Check what comes out of the old filter for water/debris and look for anywhere the system could be pulling air. The long crank getting progressively worse definitely sounds like something worth chasing on the low-pressure fuel side.

 

[Bob R1]

9/03/2026
I changed the Fuel Filter.
Now I can not get the Priming Pump to fill the new Mahindra Fuel Filter.
Any ideas before taking it to the shop??

Bob R

 

[USMC]

It sounds like you have a vacuum lock or an open in the fuel line somewhere Bob.

Go old school and put the output line in a can of fuel and run the pump. It will let you know if the system is venting when it shouldn't and whether there is excessive air in the system.

 

[Bob R1]

09/04/2026
Update: After my attempt at manual priming the Filter, I pulled the Filter Assembly and it had NO Fuel in it.
After talking with my local diesel shop guy I decided to provide fuel from a different source than the factory fuel line to the Fuel Tank. I put a 3/8 fuel line in the side of a 1 gallon plastic pail using a 3/8 Barb Fitting. I connected the 3/8 Fuel Line to the GREEN Radiator Side fuel port on the Fuel Filter. I set this pail on the area on the top front of the radiator which made it elevated to the filter assembly. I poured diesel fuel in the plastic container using a micro fiber towel as a filter.
I was then able to manually prime the Filter assembly.
Start number one took a little more cranking than I was happy with. However it did a quick restart after turning it off. I also restarted it two times after letting the Roxor set for probably one half hour and the next time over two hours.
It is looking like my problem is in between the Fuel Filter, and the Fuel Tank.
Looking like I will need to drain the tank and drop it next.

So Far I have not determined if the 2024 Roxor with the 2.7L has an Electric Fuel/Lift Pump in the Fuel Tank. Every after market source with any information on the pump, has no mention of what year models have the pump. All write up seem to be by Diesel Freak. They mention a Problematic Pump Fuse located under the dash on the passenger side. I did not locate a fuse in that location. As my luck would have it Wade is off work at the moment. So I have not been able to ask him any questions.

More to come.

Bob R

 

[USMC]

Bob, check out the Hand Primer in the fuel filter pdf (1F).

 

[Bob R1]

I changed the Fuel Filter, and I could not get the hand pump to prime the system.
I next connected a remote fuel line to the filter supply using a 1 gallon can as the fuel tank. The system then primed and started as usual.

Looks like the Fuel Problem is between the Filter and the end or the Fuel pick-up in the tank.

TANK
This is a problem area. To start with the 2024 no longer has the Drain Plug in the bottom of the fuel tank to drain Water and or Fuel to get the Fuel Tank lite enough to handle by hand.
No problem use an Arkansas Credit Card. That is a no go as the Fuel Filler Hose has something in the middle of the hose to block a siphon hose.
Next Big Problem the back Fuel Tank Bolts have their Nuts in a hole that is not accessible with the Cecco Racing Farm Bumper installed.
What I ended up doing was to take one front fuel tank bolt at a time out and replace it with a 3" Bolt. I then lowered the front of the Fuel Tank using my Bad Lands 1.5 Ton Off Road Jack. With the front of the tank down I had enough room to get my hand in above the fuel tank and unlock the Quick Connect Fuel Line from the tank. I then removed the fuel line from the vehicle. It is one piece from Filter to Fuel Tank.

FUEL LINE
Wiping down the Fuel Supply Line, end to end I found nothing suspicious. Next I removed the Plastic Ribbed Wire Loom on the Filter end of the fuel line. (I am not sure if this plastic wire loom was protection for the fuel line, or to prevent Vapor Locking. It could have been to help prevent kinking the line changing the fuel Filter) Looking over the end of the line I discovered a Kink about 12 Inches back from the end. This kink looked bad enough to cause a crack that I could not see. My plan was to make a trip to O'Rileys, and pick up 12 feet of 3/8" Gates Barricade Fuel Line, and replace the line with rubber from Tank to Filter. I then planned to zip tie the rubber fuel line very securely. Stopping by my brothers place on the way to town to let him have a look at the fuel line. (He was a mechanic in the Air Force for 21 years) He suggested just splicing the Plastic Fuel Line. We cut out the kink and spliced the line with a 3/8" Brass Compression Connector using a couple Nylon Ferrules.
I put everything back together, the system primed as normal, and the Roxor started right up.

With Fingers Crossed, and a little luck the problem is cured.

While tracking down the Fuel Filter at the Farm Supply (Mahindra Dealer) I also picked up a new Air Filter. At close to 8K it did not look real bad, but I changed it anyway.
While under the Roxor I discovered the Rear Pinion Seal has been leaking a little. Looks like I need to check the fill level on it also.

Bob R

 

[Ted]

Hi Bob, I’m glad you figured it out and spliced, I wonder what would have caused the kink? Mine will infrequently take a few extra seconds to start. I will keep this in mind if it becomes more regular. Thanks for your thorough updates and follow through!
Ted

 

[marschb]

Thanks for this. I just picked up a 2024. This is great information.