Thread: 03 TD5 fuel issue - Disco struggling to start, intermittently.

I think it is the fuel pump I have a customer with a leaking Fpr and he has no problem when mine was leaking I had no problems , amigos will not be related in any way

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X2 for fuel pump , but you will Probably want to change fpr anyway

If you put 75 litres into it, it wasn't a quarter full.
It's a long shot, but you may just be running very low on fuel. When mine ran out completely, all I got into it was 90.4 litres.

How'd you go with fixing ya problem?
After replacing fuel pump, filter, glow plugs and new fpr mine still had starting issues, I pulled fpr off myself and checked gauze filter in block gave it a good blow out and fitted new gaskets, still was the same so I replaced copper washers and o rings on injectors and seems I was there I replaced injector loom and now there are no issues at all ��
Cheers Rob

Similar experience to the previous post with my 02 Td5 some years back.


Difficult starting and occasionally engine actually died while driving...
Techs worked from fuel tank forward (less costly to more costly) - fuel pump replaced (twice), filter as there was a tech bulletin about seals or something, pump relay contacts were burnt, then did injector seals and all was good.

Hello again all.

Slightly embarrassed to report that I haven't attempted to correct this problem yet - have been avoiding letting fuel level fall so low as to begin to have fuel delivery issues.

I replaced the gasket and all the o-rings on the FPR but it leaks as steadily as before (tried to cheap out - wasted my time). I have ordered a FPR rebuild kit from UK and will fit soon.

I am thinking that fuel pump replacement is the first port of call for me? Though could the injector seals be the issue? Seems a few of you have rectified delivery issues by replacing the seals?

Thanks guys,
Aaron.

Yes it could be injector seals, mine had been getting sluggish to start recently, although not related to how much fuel was in the tank. Eventually it stopped on me in the middle of Ipswich road in stop start traffic and I flattened the battery trying to get it started again. Replaced injector seals and all is good again. Genuine copper washers, o-rings and bolts from MR Automotive was $152.00 delivered. Certainly a lot cheaper than a new fuel pump. Rave says to torque the bolts to 24 ft/lbs, but the guys at MR say to go much higher, I went to 45 ft/lbs and it felt like the bolts were starting to stretch. This is why new bolts are recommended. I hope you get it sorted soon.

Cheers, Mick.

My experience with leaking injector seals was it was always difficult to start and needed bleeding when left to sit overnight or extended periods regardless of the fuel level.

If it is any consolation the fuel pressure regulator, injector seals, and fuel pump all seem to fail one after the other at about the same age - along with other easy to replace parts which have rubber or plastic components in them. So if you are happy to do some preventative maintenance, even if do all you will know these should be sorted for another 250k or 10 years.