Thread: DEAD Disco - 300tdi won't start

ugh, not such a short story anymore.

While under the car and looking around, we also noticed another little issue.

the bloody gearbox sump plug was MISSING! flat out gone!

obviously this is a massive issue within itself, BUT even in a worst case scenario and the gearbox is knackered, doesnt really explain why the engine wouldn't start.

Im thinking (hoping like all hell!) the engine issue is seperate, and is a bessing in disguise that we found the missing sump plug

before this, the gearbox showed no signs of damage though. still smooth, easy into gear etc.

Today is also the first time i've driven it in a week, but had been driving it around for about half an hour without issue before all this...it literally seemed to go from 100% to dead, in one turn...

The missing plug is probably the wading plug, rather than a sump plug.

As far as the running fault, my first port of call would be the fuel lift pump or the shut off solenoid on the injection pump.

OK, first up, 300Tdi's are notorious for having a dodgy connector on the fuel pump solenoid.

Check that the female spade is still on the male spade, remove the female connector and clean up the male terminal with some scotchbrite pad.
It's a bitch to get at, but do that, and maybe try and close the female connector up slightly and push it back onto the male terminal after giving both a liberal spray of electrical contact cleaner, if available.

If the engine still refuses to fire, crack the bleed screw on top of the fuel filter and crank the engine.
If fuel isn't coming out of here, either a fuel line is cracked (sucking air) or the lift pump is cactus.

Next step is check the filter and sedimenter (if fitted) for a blockage.




As for the missing plug, are you sure you aren't seeing the 1/2" BSP plug hole in the bell housing under the flywheel ?
This is just for locking the flywheel when servicing the timing belt and pump timing adjustments. It's normally left out although it's recommended to install during creek/river crossings.

The R380 drain plug is (was ?) a big hex headed plug on the drivers side of the g/box facing the front prop shaft.

Something similar happened to me with my 300tdi Defender. This was in the UK and my first thooughts were to check and replace the glow plugs. No joy there. It turned out to be a pin hole in one of the flexible pipes used to return unused fuel to the tank. This caused terrible starting problems and a considerable lack of power.

Not sure if it's pertinient to your problem, but perhaps it's worth a check. After runiing the engine, try wiping the pipes with a tissue. The evidence will be obvious.

thanks the replies!

i've lined up a mate's hilux for towing duties tomorrow, so will at least get her back in my own driveway

Here's a pic of the missing "sump" plug. looks like it is minor, but there's still a bit of oil around it. signs of a leaky rear main seal perhaps?...



now this lift pump. We figured there was one, due to the 15amp fuse in the fuse block, but under the light of mobile phones couldn't for the life of us find where the actual wires/connections are for it!
Are they under the boot carpet? under the chassis somewhere?

It seems pretty likely a wire has shaken loose, or the pump is dead, so this'll be the first thing on the checklist tomorrow!

The missing plug is the wading plug for the flywheel drainage hole. It shouldn't be fitted unless you are going to play in the water for any extended period of time.
As for the (mechanical, no cables or fuses here) lift pump, it is on the left hand side of the block, if you are standing in front of your vehicle, easy to access, and it has a little handle. Try moving this handle and see if you have some resistance, i.e. "prime it. The injection pump on your Disco is a mechanical one, so no issues here suspected. The shut off solenoid shouldn't give any trouble like this. If it fails to open, your engine won't start. In your scenario you apparently have enough fuel for letting the engine run smooth on idle, but as soon as you drop the throttle the trouble starts. Sounds like a fuel supply problem.
Glow plugs are not really necessary on your engine, especially when already running. A failure here wouldn't cause the symptoms described. Rick's hints above are worth checking.

colapsed inter cooler pipe, check the bend one close to turbo
cheers
blaze

Originally Posted by bblaze

colapsed inter cooler pipe, check the bend one close to turbo
cheers
blaze

checked over all the intake piping, all looks fine.

Bout to head back and start assessing the lift pump! fingers crossed we get somewhere