Semi urgent help required

[chilla]

2003 TD5 210,000km 7 seater. Went through a touchless car wash yesterday with engine off and air con on. Upon leaving, engine wouldnt rev past 3000rpm and about 40km/hr. Pulled over and turned engine off, couldnt restart. Coudnt hear fuel pump turn on with ignition. Did the accelerator on/off 5 times procedure and tapped some random fuses/relays and could vaguely hear fuel pump. Engine started and I drove home fine. Just then, it broke down again. Had to tow it home. The boys at M R Automotive suggested fuel pump yesterday and now that I can't hear it at all, even after the accelerator pump 5times, maybe they're right.
Any tips on ripping the carpet up to get to the fuel pump? I want to whack a multimeter on it and test for voltage. If there is power there and I need to order a new pump, where's the best place to source one?
Sorry, I've only had the car maybe 3 weeks now and still trying to find things out. What's the best places to get parts for these things? I'm hoping to order, receive and fit the fuel pump so I can take my family camping on the weekend...am I dreaming?

[Rok_Dr]

Here you go, the definitive how to.

www.discovery2.co.uk / TD5 Fuel Pump replacement. (http://www.discovery2.co.uk/fuel_pump.html)

As to pumps if you are planning on keeping the car for a while go for a genuine or OEM manufacturer part, which in this case I believe is VDO. Cheapest may not be the best quality. Try Roverlord on the forum here, as they may be able to ship one overnight if they have one in stock

Good luck

Cheers

Steve

[Bohica]

Here you go, the definitive how to.

www.discovery2.co.uk / TD5 Fuel Pump replacement. (http://www.discovery2.co.uk/fuel_pump.html)




x2 and ditto on the genuine or OEM.

[PhilipA]

If you want to avoid taking all the trim out, just get a Stanley knife and run it along both sides, preferably as far under the bins as you can manage.ie lean the blade over.
You can then roll the carpet far enough forward to get to the plate over the fuel pump.

When you put the carpet back down you cannot see the cut.
Regards Philip A

[chilla]

Update: Interestingly, once I got to the fuel pump, I d/c the plug and checked for power. Power on the plug was ok. As soon as I reconnected plug, the pump came to life and started buzzing. I turned her over and she started up with a little delay and push on the pedal. Unfortunately, I forgot I slightly loosened one of the hose lines to see how the connectors worked and the hose popped off spraying diesel everywhere :oops2: Anyway, after remembering something I thought I saw on one of the receipts left from the previous owner, I realised the fuel pump had been replaced late last year, on the previous owners behalf, with a genuine VDO pump by M R Automotive. So either the fuel pump is intermittently faulty (I don't think that's the problem) or there is a wiring issue (seems more likely to me). I couldn't fault the wiring on the plug or the plug itself. So does anyone know where the relay that provides power to the fuel pump is found? (I'm assuming there is a control relay for the pump). An intermittent dodgy relay sounds more like the culprit to me, than a 6 month old VDO fuel pump playing up. Also, is the wiring from the relay to the pump a solid run, or is there a connection that may have come loose somewhere along the way?
By the way, I've only had her a few weeks, so would the experienced owners please tell me if they would continue to drive around, or if they would order another fuel pump and have it ready to swap out. Apart from locating and swapping out the relay, I'm not sure what else I could do.

[Outback 1]

If you want to avoid taking all the trim out, just get a Stanley knife and run it along both sides, preferably as far under the bins as you can manage.ie lean the blade over.
You can then roll the carpet far enough forward to get to the plate over the fuel pump.

When you put the carpet back down you cannot see the cut.
Regards Philip A
Not necessary to cut it Philip it's precut from the factory you just need to tuck the edge back under the bins as you fit it back in place


Sent from my SM-G900I using AULRO mobile app

[Outback 1]

Fuel pump relay is in the under bonnet fuse box diagram inside the cover

Sent from my SM-G900I using AULRO mobile app

[schuy1]

relay is found in the engine bay fuse box. It is possible it just needs taking out and reinserting, although they can play up. It may also have been a loose conection at the pump thta you rectified by repluging.

[schuy1]

dang! beaten by the outback! :D

[Rok_Dr]

Don't over complicate it. A poor electrical connection at the plug is a more likely scenario, particularly given its been recently changed and the recent car wash drenching.

If you haven't already done so give the plug and pump terminals a good clean with contact cleaner and check that none of the spade terminals in the plug have been pushed back due to a slight misalignment. If so then push the offending one back in its proper position and gently replug.

As to relays check the owners manual but I think it's located in the under bonnet fuse box and can be swapped with the same coloured one for fault diagnosis.

Cheers

Steve

[Rok_Dr]

And ignore last sentence outback1 and schuy1 can type faster than me:D:D:D

[chilla]

So I'm not exactly sure what you 3 are trying to say. Are you saying, that it may be possible, the relay could be found in the under bonnet fuse box?? ;)

[Rok_Dr]

Yes that's correct.


Fuel pump relay is in the under bonnet fuse box diagram inside the cover

Cheers

Steve

[chilla]

Sorry Steve, I was just messing around. It was clear that's what you meant as three of you said the exact same thing straight after each other. My plan when I get home today is to swap the fuel pump relay to another spot and see if the intermittent fault moves with it. Thanks for the help.

[chilla]

So I've swapped out the fuel pump relay with the washer relay. Also checked the ECU plug and there was a small amount of oil which I sprayed with contact cleaner and cleaned out. Just have to see what happens I guess. Which kinda sucks, because I'd like to plan some trips away in the upcoming weekends, but don't feel confident to do so. Hope this isn't the Land Rover Life haha.

[Rok_Dr]

I reckon you'll be ok now. All part of getting to know a new car and in my experience there always will be a few issues to sort out initially.

And in future avoid those car washes :D:D:D

Cheers

Steve

[chilla]

I took it for a drive to mt gravatt, approx 40km, drove fine. Sat there about 3-4hrs, then within 3 or 4 mins of driving, couldn't rev engine then she broke down. Unplugged fuel pump, reconnected, started fine and drove home the 40km with ease. Same thing happened to the mrs couple of days earlier. Did a 15km trip fine, then when restarted, conked out in the first 3 or 4 mins. Fuel pump does make a funny sound when I turn the ignition come to think of it. Either an intermittent dodgy fuel pump (is this common or possible?) Or a dodgy connection on plug or wire close to olug that moves when I d/c and reconnect plug.

[discorevy]

An intermittent fuel pump fault is possible, but when you say the fuel pump is making a funny sound if it sounds something like a strangled cat ( imagining only :-) then your fuel injector washers might be leaking, if you pull the pump again and see a black carbon stain on the pump that is a good indication as when they leak combustion gases are carried back to the tank , this is also what causes the pump to cavitate making the funny noise and causing no start or power, just another possibility, but worth a check.

[chilla]

The funny sound only last about 2 seconds after I click to ignition, then normal fuel pump noise. Almost sounds like there is air in there, or possibly a strangled cat (not from personal experience). Are you able to post videos here? If so I'll film it when I get home. Or just upload to youtube and paste a link.

[discorevy]

I'd be doing the washers and o rings , if your semi handy with spanners, take you about 2-3 hours , let us know how you go

[chilla]

Might give it a crack next week if I get some time. What's the best place to get those sort of spare parts from?

[chilla]

Problem solvered...I think.
I noticed when I wiggled the plug slightly, (see video), the fuel pump would cut in and out. I jammed a multi meter in the back of the plug while still connected and noted when the fuel pump cut out, the power was still present. This told me the wiring, relay, relay base etc from the plug backwards was most likely ok. I also noticed the male + pin on the fuel pump was discoloured and the white plastic on the bottom was slightly melted (top right pin in picture attached). I was hoping this was a result from a bad connection on the plug, not an issue with the fuel pump itself and hadn't become to hot to cause an issue with the pump. I got hold of an old unused fuel pump plug and about 15cm of its wiring loom. I disconnected existing plug and cut wires and simply in-line joined the new plug. Seems good to me. Only time will tell. I'm pretty confident though. Thanks to all for the help.

https://www.youtube.com/watch?v=vR48PP2F4ZQ

http://i197.photobucket.com/albums/aa59/triccytriddy/20160516_170236_resized_1.jpg

[discorevy]

Seems like you sussed it .......good one :)