Td5 starting problem - any ideas

[jwb]

Have been through the archives but not found my exact problem - the technicians are struggling too.

I have a 2002 D2 Td5 and late last year the fuel pump got very noisy and the car was difficult to start intermittently.

1. Replaced fuel pump and filter
2. Still intermittently hard to start - engine turns but wont fire, fuel pump noisy, can start after considerable throttle pumping then runs fine for a few days
3. Second fuel pump installed and a component in the fuel filter which is the subject of a tech bulletin, fuel pump relay replaced as contacts are burnt.
4. Runs fine for a week normal starting etc
5. Starts to run rough and not idle one day and engine stops, am able to restart following the fuel purge procedure and get it into the shop but it has no power and missing badly, computer fault notes fuel pump running
6. Techs suspect ECU or injector seals as the fuel pump runs hard/noisy as if it is continually purging the fuel line.
7. Replacement ECU fitted, didn't fix the problem, now doing the seals....

No oil in loom,

[DEFENDERZOOK]

id be checking the pickup in the tank......it may be blocked......or possibly even the breather for the tank.......


next time it wont start......remove the fuel cap and see what happens......

the problem sounds like its coming from before the pump......as the pump is strugling......
so i dont think the injectors are the cause......or anything up to that point.......

[Blknight.aus]

could be a damaged pickup as already mentioned but it could also be the fuel pressure regulator sticking open and allowing the pressure to drop/not build...

double check the oil levels as an injector pumping dieso into the oil is bad and can occasionally give some funny symptoms (based on cats which use a similar injector).

Also remove the fuel return line and make sure that with the engine stationary that clear bubbless fuel comes through (a few little ones are ok) and then start the engine if it the fuel flow has a hissy fit then you might have an injector problem.

[Graeme]

I'd connect a pressure gauge in place of the fuel temp sender to verify that the pressure is low. At least if its not then you can rule out the fuel pump, filter and pressure regulator although there could still be a problem with the pressure regulator housing, including the mesh filter that sits in the head under the regulator housing.

Note that the fuel pump runs continuously except if the engine is not started within a short time (30 secs IIRC).

Pumping the acceletator does nothing until the engine has started, as the pedal input is ignored whilst cranking.

[Blknight.aus]

if you hold the accelerator flat to the floor prior to starting and keep it held flat to the floor the engine goes into purge mode....

DOnt do this repeatedly.

[jwb]

Update and info for others. They changed the injector seals and it appears to have fixed the problem.

Normal starting (at least the last few days) and the fuel pump is completely silent. I didn't notice any excessive fuel usage prior to this or increase in oil level however in hindsight probably noted a progressive performance reduction.

[LandyAndy]

How full is the sump!!!!
Didnt I read on here that when they leak it goes into the sump????
May have my wires crossed but could need a oil change asap.Im sure others will pick up on this.
Andrew

[zaher]

Dear all

I had the same problem as I mentioned in the previous comment but now the problem have increased. The 2004 disco td5 does not start at all even with an ignition spray. I read every thread about this issue and summarized all the possible problems.

glow plugs. cranckshaft sensor, fuel line, earth wiring, filter sensor, non return diesel, injectors loom, injectors rings, fuel temp sensor, eco reset, dirty injector harness, immobilizer and fuel purge. DID I MISS SOMETHING!!!

And we checked and fixed them all

Now they are telling me it might be a weak ingine itself!! cause we did all the other possibilities.
The issue is that the previous owner flatted the Head of engine after he drove without water. and he says now the problem of the ignition issue started after he did the head.

pump is new, no white/gray smoke at start (when it used to start )

PLEASE, some help. i got lost with all the possibilities and its so costy,

thanks in advance

zaher

[Blknight.aus]

do a compression check and leak down check on the 4 pots that have glow plugs.

your initial symptoms were cause by lower injector seal failure that let combustion gasses into the fuel gallery. This set of symptoms are probably a gasket thats gone between cylinders and is robbing you of compression.

[Sitec]

Dear all
The issue is that the previous owner flatted the Head of engine after he drove without water. and he says now the problem of the ignition issue started after he did the head.
zaher

Me thinks the answer is right there..... 'After he did the head.....'. If you bought that vehicle as a non runner after the previous owner cooked it, then attempted to fix it (that's how I read it), then I'd be checking the cam to crank timing.. A few teeth out and valves/pistons might not meet, but it won't run either! If the valves are opening too soon, too late, or... not at all, the motor will never fire up even with a dose of ether. If the camshaft is not rotating, you can do a compression test and 4 of the 5 pots will have compression... Go back to the 'kiss' theory and start from the beginning. Lift the rocker cover off and crank it and see what's happening. If stuff is turning, great. Now pin the flywheel, and see where the cam is at. Be prepared for valve/piston damage if the cam is out. My fingers are crossed!! Good luck and don't let it get the better of you!! :)

[alien]

Dear all

I had the same problem as I mentioned in the previous comment but now the problem have increased. The 2004 disco td5 does not start at all even with an ignition spray. I read every thread about this issue and summarized all the possible problems.

glow plugs. cranckshaft sensor, fuel line, earth wiring, filter sensor, non return diesel, injectors loom, injectors rings, fuel temp sensor, eco reset, dirty injector harness, immobilizer and fuel purge. DID I MISS SOMETHING!!!

And we checked and fixed them all

Now they are telling me it might be a weak ingine itself!! cause we did all the other possibilities.
The issue is that the previous owner flatted the Head of engine after he drove without water. and he says now the problem of the ignition issue started after he did the head.

pump is new, no white/gray smoke at start (when it used to start )

PLEASE, some help. i got lost with all the possibilities and its so costy,

thanks in advance

zaher
As the head has been done I'd suggest checking the cam timing.
I looked at one a while ago that was out a tooth and wouldn't fire.
Once it was reset it fired easily:)

[zaher]

Hi ALL
THANKS FOR HELPING.

At the end, I replaced the injectors though it was the last thing to replace. meanwhile the td5 start and run easily at the beginning and in low speeds, the problem shifted to high speed, it loose the power when it speed to 50-70 kmh (36-50 mph) and when it reach an ascent, it slow down and loose the power.

To remind you of the sequence of the events.

was heated and fixed the head, ignition problems, fixed all ignition and gaz options, changed the injectors and the problem swap to low power when speeding.

I highly appreciate any help, though i began to be desperate

thanks

zaher