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Thread: Fuel Supply Problem

  1. #1
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    Fuel Supply Problem

    Hi all jumped in the '96 300tdi manual today and it ran out of power going up a hill and eventually stalled when I pulled over. Took a few tries to get it going again. I had noticed that it was lacking power down low and a little hesitant to get going. Anyway, I went home and put a new fuel filter on and it started and idled, but still hesitant to get going, stalled and took a while to start.

    Took a good lift pump and put it on (lift pump on it was new about 600 km ago). No change.

    Pulled sedimenter apart, cleaned and checked it was sealed etc. No change.

    Checked all fuel lines - all good (they were all replaced about 5 years ago.

    My thoughts are that the fuel stop solenoid is faulty. Reading on youtube, the loss of power and stalling intermittently, but (when running) idles ok is common for a faulty solenoid.

    Any thoughts/suggestions?

    Edit: until this problem it was starting instantly hot or cold which would indicate (likely) no fuel leaks.
    1996 Disco 1 300TDI manual - Lucille a cantankerous red head! :D
    1997 Disco 1 300TDI Auto - sold

  2. #2
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    Hi Tom, might be worth checking inside the turbo hoses. They can delaminate inside restricting air flow and cause lack of power.
    Hope you find something easily fixed.
    Cheers,
    Woolly.

  3. #3
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    Quote Originally Posted by Woolly View Post
    Hi Tom, might be worth checking inside the turbo hoses. They can delaminate inside restricting air flow and cause lack of power.
    Hope you find something easily fixed.
    Cheers,
    Woolly.
    Hi Woolly, hoses appear fine.

    Cheers,
    Tom.
    1996 Disco 1 300TDI manual - Lucille a cantankerous red head! :D
    1997 Disco 1 300TDI Auto - sold

  4. #4
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    I have replaced the fuel stop solenoid and fuel lines and no change. I have checked all the turbo pipes, all good. I put a little electric fuel pump on and it works fine. But it still runs out of diesel. I can undo the primer on top of the filter and the electric pump takes a few seconds to pump diesel up.

    I can come out in the morning and it starts first time, but hesitates when accelerating (no load), lacks power and after a few minutes stalls

    Is it possible that the injector return pipe is leaking and causing this problem? It has relatively new washers and pipe along the top (about a week ago) and it has done ~500km fine with that. Any ideas?
    1996 Disco 1 300TDI manual - Lucille a cantankerous red head! :D
    1997 Disco 1 300TDI Auto - sold

  5. #5
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    Quote Originally Posted by BathurstTom View Post
    I have replaced the fuel stop solenoid and fuel lines and no change. I have checked all the turbo pipes, all good. I put a little electric fuel pump on and it works fine. But it still runs out of diesel. I can undo the primer on top of the filter and the electric pump takes a few seconds to pump diesel up.

    I can come out in the morning and it starts first time, but hesitates when accelerating (no load), lacks power and after a few minutes stalls

    Is it possible that the injector return pipe is leaking and causing this problem? It has relatively new washers and pipe along the top (about a week ago) and it has done ~500km fine with that. Any ideas?
    Ok. guessing... When it stalls, do you need to bleed it before it will start again?

    Did you hook up the electric pump in place of or in tandem with the mechanical pump? Does the electric pump have sufficient capacity to supply fuel for the TDi? IMO the lecky pump is a bit of a red herring, adding another variable. Don't blame you for trying though. I'd be suspicious of the lift pump too if it were me.

    Is there any possibility that some activity recently could have crushed a fuel pipe? Have you tried doing a flow test? A simple one, where you undo a fuel pipe after the pump (either one) and see if the flow is continuous or if it dwindles after some time.

    Like I said, guessing, but it sure sounds like it's starving for fuel. If you don't need to bleed it then I'd say there's a blockage, if you do then it's probably an air leak, although if air can get in then diesel can get out.

    And one for the gurus: Is the D1 tank sealed, or is the cap vented? IDR. If it's sealed then could it be creating a vacuum due to something like a blocked return line?
    ​JayTee

    Nullus Anxietus

    ​Getting involved in discussions is the best way to learn.

    2000 D2 TD5 Auto: Tins
    1994 D1 300TDi Manual: Dave
    1980 SIII Petrol Tray: Doris
    OKApotamus #74
    Nanocom, D2 TD5 only.

  6. #6
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    Just looked at my fuel cap and also checked with the w/s manual, they are definitely vented, and the manual says by a two way valve.
    Cheers,
    Woolly.

  7. #7
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    Quote Originally Posted by Woolly;[URL="tel:3180517"
    3180517[/URL]]Just looked at my fuel cap and also checked with the w/s manual, they are definitely vented, and the manual says by a two way valve.
    Cheers,
    Woolly.
    So, if the vent is blocked maybe the tank is creating a vac. Still guessing.
    ​JayTee

    Nullus Anxietus

    ​Getting involved in discussions is the best way to learn.

    2000 D2 TD5 Auto: Tins
    1994 D1 300TDi Manual: Dave
    1980 SIII Petrol Tray: Doris
    OKApotamus #74
    Nanocom, D2 TD5 only.

  8. #8
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    Quote Originally Posted by Tins View Post
    Ok. guessing... When it stalls, do you need to bleed it before it will start again? Yes, or wait until it seems to fill back up (trickle?) after perhaps an hour or two.

    Did you hook up the electric pump in place of or in tandem with the mechanical pump? In tandem

    Does the electric pump have sufficient capacity to supply fuel for the TDi? Yes
    IMO the lecky pump is a bit of a red herring, adding another variable. Don't blame you for trying though. I'd be suspicious of the lift pump too if it were me.

    Is there any possibility that some activity recently could have crushed a fuel pipe? Pulled out the sender unit from the tank and checked it. It is clean and working fine with no leaks. Installed all new line from sender to lift pump this morning - no change.

    Have you tried doing a flow test? A simple one, where you undo a fuel pipe after the pump (either one) and see if the flow is continuous or if it dwindles after some time. Yes, I accidentally let the pipe drop and lost about 40 litres

    Like I said, guessing, but it sure sounds like it's starving for fuel. If you don't need to bleed it then I'd say there's a blockage, if you do then it's probably an air leak, although if air can get in then diesel can get out.

    And one for the gurus: Is the D1 tank sealed, or is the cap vented? Vented the cap (checked and ok) and the 300tdi tanks have a breather.
    IDR. If it's sealed then could it be creating a vacuum due to something like a blocked return line?


    Further to the above questions, I checked the vacuum pipes from the boost diaphragm to the turbo - all good. The Boost pin was a little sticky to get out so I cleaned that out. Diaphragm is good.

    The last thing that I will try is to crack all the lines after the lift pump through to the injectors to see if there is an air lock in the injector pump.
    1996 Disco 1 300TDI manual - Lucille a cantankerous red head! :D
    1997 Disco 1 300TDI Auto - sold

  9. #9
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    Quote Originally Posted by BathurstTom View Post
    Further to the above questions, I checked the vacuum pipes from the boost diaphragm to the turbo - all good. The Boost pin was a little sticky to get out so I cleaned that out. Diaphragm is good.

    The last thing that I will try is to crack all the lines after the lift pump through to the injectors to see if there is an air lock in the injector pump.
    If you need to bleed it then that would be my first place to look. Besides, there isn't a whole lot else. Unless the air side is blocked I guess. Pretty simple thing, the TDi.
    ​JayTee

    Nullus Anxietus

    ​Getting involved in discussions is the best way to learn.

    2000 D2 TD5 Auto: Tins
    1994 D1 300TDi Manual: Dave
    1980 SIII Petrol Tray: Doris
    OKApotamus #74
    Nanocom, D2 TD5 only.

  10. #10
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    I noticed in your OP that you "Pulled sedimenter apart, cleaned and checked it was sealed etc. No change." and that reminded of an incident that occurred with a friends 300Tdi D1 at 80 mile beach in WA many decades ago.

    I took advantage of the service pit next to the kiosk there and did a full service on friends Disco, including removing, completely dismantling, cleaning and reassembling the sedimenter. After the service the Disco exhibited similar symptoms to what you describe.

    Anyway, to cut a long story short, I finally found that the rubber washer on the sedimenter drain plug had developed a lip around the edge due to the plug being a slightly smalled diameter then the rubber washer. Anyway, when I reassembled it the lip must have caught on something and was allowing air to enter the fuel system.

    The problem was rectified by simply & quickly by turning the rubber washer over and refitting
    - sometimes it's the simple things in life that can cause us the most angst.

    It wouldn't take long to try turning yours over (or fit a new one) and see what happens

    Good luck.

    Roger


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