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

**Trolley** · 25th May 2015, 11:51 AM

Hi all

Having a little issue with my 03 TD5 Disco.

A couple of weeks ago - actually immediately after I bought the car, it wouldn't start. Called RACQ and the fellow shows up - connects his jumpstarter and it still wouldn't start, although it was turning over and over and over. There was a loud whining sound coming from the fuel pump, followed by a small gargling sort of sound, then near silence from the pump.

The car eventually coughed to life by flooring the accelerator pedal. The RACQ fellow suggested that the fuel pump was nearly knackered and that perhaps the diesel that was in the car was bad. He suggested that I let it run for 10 minutes and go and put a full tank of fresh diesel in it.

I did, and has been starting fine ever since (3 weeks) with no whine from the fuel pump. However, I have never let the fuel get below 1/4 full.

This morning, with the fuel indicator below 1/4 full, I had the exact same problem as the other week; loud whine followed by gargle but still couldn't start without flooring the accelerator and having it cough white smoke and eventually run. I let it sit idling for 10ish minutes and then went down to the fuel station and put 75 litres in it. Started fine and is running very well with a full tank.

So - the question is what's the problem? Why does this happen when the fuel is low and not at other times? I have started it maybe 50-75 times in the 3 weeks and it has not had an issue when the tank is more full than, roughly, 1/4 of a tank.

Also, I intermittently have the 'water in fuel' light come on the dash. It seems to be more prevalent when fuel is low, but that could be psychological. Further, it seems to be running smoother and with more power with the fuel tank full - again, could be in my mind.

Is my fuel indicator buggered?
Is my fuel pump really dying? (new car to me, not sure how old pump is).
Does my fuel filter need replacing?
Air in fuel lines?
Oil in ECU?

Any guidance here would be very greatly appreciated.

Thanks,
Aaron.

**Outback 1** · 25th May 2015, 12:38 PM

I would think that the pump may be on its way out. the water indicator light could be a wire rubbed through mine does the same thing the first time it did it i drained the filter and no sign of water but occasionally it still flashes on

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**Killer** · 25th May 2015, 12:49 PM

There is a little membrane filter on the return line out of the fuel filter, it is designed to let air through but not fuel. After a while it does not let the air through and the system will not self bleed. Replace it and I believe your problems will be solved.

Cheers, Mick.

**Trolley** · 25th May 2015, 01:23 PM

Originally Posted by Killer

There is a little membrane filter on the return line out of the fuel filter, it is designed to let air through but not fuel. After a while it does not let the air through and the system will not self bleed. Replace it and I believe your problems will be solved.

Cheers, Mick.

Thanks for the speedy response. I have been reading a little about this and it sounds like it might be correct - can you point me in the direction of this membrane? Where can I find the part? Did you mean replace the fuel filter in its entirety? Wouldn't be a bad idea I suppose, given they are cheap.

Thanks,
Aaron.

**Jason789** · 25th May 2015, 02:05 PM

Check for oil in the engine loom. I had similar problems with intermittent hard to start problems.

Cheers,

Jason

**Killer** · 25th May 2015, 02:08 PM

Replacing the actual fuel filter would be a good idea, but this is a seperate part. I purchased mine from FWD Motors in Yerongpilly, MR Automotive at Redcliffe would have them also. On the fuel filter body, (the bit that the filter srews onto) there are four fuel lines going to it. This membrane filter fits in line to one of the fuel lines. From memory it is a brass fitting with what looks like a nylon plug in it. I paid about $30 for mine a year or two ago. I hope this helps, there is diagram on the forum, showing it as an exploded view but I don't have time to search for it, sorry.

Cheers,
Mick.

**Trolley** · 25th May 2015, 02:38 PM

http://picturestack.com/383/883/3D4Td5FuelFilj9R.jpg

I see what you are talking about - I'll pick one up and install. My fuel filter has done 60000Kms too, so that is going too.

Jason789, I will have a look now. Thanks mate.

ta,
Aaron.

**Trolley** · 25th May 2015, 03:52 PM

Originally Posted by Jason789

Check for oil in the engine loom. I had similar problems with intermittent hard to start problems.

Cheers,

Jason

Checked the ecu and there was a small amount of oil on the red plug. Cleaned if off with quick evaporating electrical cleaner and reassembled, car starts and seems to idle fine atm - but that was happening before with full tank. The presence of oil on red plug means seal on injector loom has failed, right? Which would mean I need to place injector loom?

**gusthedog** · 25th May 2015, 06:35 PM

Originally Posted by Trolley

Checked the ecu and there was a small amount of oil on the red plug. Cleaned if off with quick evaporating electrical cleaner and reassembled, car starts and seems to idle fine atm - but that was happening before with full tank. The presence of oil on red plug means seal on injector loom has failed, right? Which would mean I need to place injector loom?

Yep. Some tight wads clean the old one out but I just buy a newy every 20k-40k or so. They're pretty cheap from the UK

**Trolley** · 5th June 2015, 03:25 PM

Hi all

Replaced the air bleed valve on the top of the fuel filter housing today (part finally arrived from UK). My fuel level is currently a little under half, and I will be sure to let you know if the starting issue is still there when the fuel gets low. Hopefully the new valve will correct it!

Am I right in assuming that because the issue is air in the fuel lines, there must be a diesel leak somewhere? My FPR looks like it could be leaking - and so probably is. The FPR leak would account for air in the system?

Thanks,
Aaron.

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

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