D2a - power loss and poor fuel economy problems solved

[twr7cx]

For those that are not aware, earlier this year I purchased Phil (DiscoWhite's) old D2a. I didn't do my research properly, and ended up buying a vehicle that has been plagqued with issues - terrible fuel consumption and power cutting out. The previous owner spent a lot of time and dollars to try to solve this with no success.

I am happy to report that 8 months later, this is all solved. A few months ago I solved the power cutting out issues, and last week I managed to solve the fuel economy issue.

The power issue was solved by fitting a TD5Alive Turbo Booster Box to stop the ECU from freaking out when the boost was too much. This resulted in a different problem though, which was solved by fitting a TD5Alvie uprated MAF sensor which stopped the ECU freaking out from more air than it could handle flowing through the MAF - the alternative would have been to fit a dual channel booster box that are also available.

The fuel economy was solved by replacing the fuel line that runs on the drivers side of the head, above the inlet manifold, from the fuel pressure regulator to the front of the head - this was leaking.
A few months later I also had to rebuild the fuel pressure regulator (I used a seal and gasket kit I bought on eBay.co.uk) as this too was leaking (I could not see it leaking, only evidence of oily residue around and below it) - the incorrect gasket had been used when someone previously had worked on it (they had used the old style gasket for the early model fuel pressure regulators) and the fuel strainer was brocken - this rebuild reduced the fuel economy from 17L per 100km to 11L per 100km!

So the vehicle now has great fuel economy, and pulls hard due to the ECU tune, increased boost, EGR removal, intercooler piping and exhaust modifications. Now that it's running properly I'll look at a new intercooler for her...

Anyways, so the purpose of this thread is to let you know that the problems are fixed (finally) and to thank all the forum members that helped during the last 8 months - my threads have received a significant number of comments, thoughts, opinions, ideas and debates, all of which has helped me to find and solve the problems on the vehicle, so thanks to all.

[dswatts]

good news!
Are you saying it was leaking 6l/100k and no one noticed?

[twr7cx]

good news!
Are you saying it was leaking 6l/100k and no one noticed?

Yes, it was loosing about that much. I could see the residue on the firewall, engine and chasis, etc., but not where exactly it was leaking from. The fuel pressure regulator had also only been replaced a few months prior by the previous owner.

[bsperka]

Can you post where you got the fuel line from the regulator to the body from? Every one that I asked indicated that you couldn't get it as a separate part, so I had to buy a new regulator. It was leaking like crazy and when I replaced it, was so hard that I snapped it past the fitting!!!

[twr7cx]

Can you post where you got the fuel line from the regulator to the body from? Every one that I asked indicated that you couldn't get it as a separate part, so I had to buy a new regulator. It was leaking like crazy and when I replaced it, was so hard that I snapped it past the fitting!!!

That is correct, they are not listed as a seperate part by Land Rover.

I actually have a spare here now. I removed my leaking one, it had a pin hole in the rubber pipe. I had the rubber pipe replaced at Enzed.

You can buy them separate often on eBay.co.uk though.

I got a brand new one from Justin Cooper. Most mechanics do not replace that hose when they replace the fuel pressure regulator as it extends the work time and expense for the customer for the job (as the inlet manifold has to be removed to replace the hose, when for the fuel pressure regulator you do not have to remove the inlet manifold).