TD5 Gurus please hep

[sdt463]

The vehicle is a 1999 dual cab tray back 130, EGR removed, TRS remap and a D2a inter cooler. It was also fitted with silicon hoses just before the start of my problems(probably coincidence).

After the motor started to miss, we noticed a high pitched scream coming from the fuel pump. This was accompanied by a lot of bubbling and knocking sounds from the fuel tank Thinking I had a fuel pump failure I managed to limp 200 kms home, but after fitting a new fuel pump I still have a very sick Defender.

Problems are.
Hard to start and when it does, only on a couple of cylinders and wont rev. Other cylinders slowly come in as it warms up but still misses if you try to rev it and blows out clouds of smoke, the more throttle you give it the more smoke comes out the back. If you can get it up to 2000RPM it starts to run smoother
So far I have fitted a new Fuel pump and filter, cleaned the plugs on the computer, removed turbo hose to manifold as I had only fitted the silicon hoses that week and thought maybe there had been a bit of packing material in one. All to no avail. This problem also started about 70 kms after filling with fuel although I could not see any water in the filter when I changed it. I have a Nanacom but must admit to not understanding all the information it gives me.
All suggestions or help to work through the problem gratefully received.
Dave :(
Ps vehicle has not been overheated and is not losing water or pressurizing.

[gazk]

Have you checked for oil in the injector harness at the red ECU plug and the wiring connector on the cylinder head ?

[justinc]

I would suspect a lower sealing washer failure, allowing combustion gasses into the fuel gallery.

JC

[sdt463]

Thanks Gazk I have given it a good clean at the computer end, I had a look at cylinder head end but it appeared clean so I just pluged it back in. In hind sight I will give that end a good clean tomorow.
Cheers Dave

[sdt463]

Thanks J C could you please tell me where the lower sealing washer is situated and if there is any way I can test if this is the case.
Cheers Dave

[robbotd5]

Not to steal Justin's thunder because he knows far more about the Td5 than I do, but the "washers" are the copper washers on the bottom of the unit injector that seals out the combustion pressure as this motor is direct injection.
The only way to check is to pull all 5 and have a look. Probably not a bad idea anyway then you will know for sure. Replace the upper "O" rings also. Use only genuine parts for this.
If a washer is crook, it will let in combustion gasses to the fuel gallery in the head making it hard to start and run like a dog. There may also be a crook injector solenoid.
Back to you JC:)
Regards
Robbo

[justinc]

Thanks robbo, been busy. You have summed it up perfectly :-) . Search on here in good oil should reveal the procedure. Jc

[Rurover]

Dave,

Don't suppose you accidentally filled it with petrol by any chance?
Or have you run a number of tanks of diesel through it since the initial pump problems?

Had similar hard to start/rough running/blowing smoke problems when I stupidly filled my Defender Td5 with petrol some years ago.
Cost me $800 from memory to have the tank drained & fuel system purged, but fortunately no lasting damage.

Alan

[sdt463]

Thanks Robbo And Justin. It would certainly exsplain the nasty noises coming from the fuel tank although I am suprised as I had the head gasket, plastick dowls and injecter washers replaced as preventartive maintenance 40,000 klm back.
Dave

[sdt463]

Hi Rurover, I did ask myself that question as it was runing great untill
I put that last tank of fuel in, but I have had a good sniff at the tank and cant pick up any petrol smell.
Cheers Dave

[Tombie]

How much you got left in that tank?
I'd be dumping it :)
And changing fuel filter...

[sdt463]

Thanks Mike My thoughts too Will Be getting rid of it first thing tomorrow.
Cheers Dave

[sdt463]

Dirty fuel.:mad: Took the new pump back out, drained and wiped out the tank, new filter and it came good instantly. Now I have just got to get the tray back on, no easy job with the second fuel tank and water tank mounted to the under side of it. This fuel came from a major fuel station on the Western Highway, just outside Ballarat. If anybody in that area wants the name feel free to pm me.
Thank you to all who posted, its really appreciated.
Dave
Ps The fuel I drained looked and smelt good.

[AndyG]

I will show my ignorance, what could be the cause:

Servo bought some nasty cheap stuff, but you said a major, so unlikely,
Dirt, rust would be caught by the filter, was this the case
Water contamination ?
Was your cap unlocked and someone took a whizz.

We worry about this in the bush, not Ballarat !
But well detected and solved, check the simplest first !

[sdt463]

I can't answer that at the moment Andy but I do Know it was not due to the car being tamped with. I was helping a friend out at the time and he paid for the fuel although I put it in, and he has the receipt. I have contacted him and asked him to look it out for me just to make sure I put Diesel in, But what I took out did not smell like petrol and looked clean.
Dave

[sdt463]

Feeling pretty Stupid tonight because although I am verry carefull filling the fender When I got the fuel reciept back today it said 61 lts ulp :o, also I cant believe I couldn't smell it. I must be losing my sense of smell as well as my marbles. Under the circumstances I have decided to let the fuel station off :D. The car seems to be running fine now is which amazing after doing 400 Ks on 75% petrol and all I can do is keep my fingers crossed I havn't damaged the injectors .
Thanks again all Dave

[AndyG]

Well you were smart enough not to name the Servo prior to completing your investigation.:)

[Tombie]

Seems you got a solution which in the end is all that matters!