Defender conked out

Shanec · Mar 21, 2016

Deacclerated toward red traffic lights.

Engine cut out suddenly within a split-second without any jerking or spluttering.

No warning at all.

Engine spinned over with starter motor.

called out recovery, and the representative who came initially diagnosed by cracking off the injectors without any fuel visible, then checked filter and it was full.

He noticed fuel had dropped onto front prop and went underneath to look upwards.

He says he suspects a gasket has deteriorated letting air in between a rusty brown cast pert and alloy on the high pressure pump.

Anyone from experience know if I should try find a gasket or just buy a new pump?

Going to sort it at weekend so will order parts tonight.

I must say I am extremely happy that I'll be working on the side of the engine bay with lots of space! Looking forward to it in a crazy way.

Saint.V8 · Mar 21, 2016

2.5TD....2.5N/A.....200 or 300Tdi...Td5...Puma...??

Stop Solenoid wire or the solenoid itself??

12V at the solenoid with ignition on?

Depending on MY and Engine....could be the Alarm 'Spider' unit....!

jamesmartin · Mar 21, 2016

get the pump leak fixed , an injection specialist would be best, it was about 100 to get the last one done i had

Shanec · Mar 21, 2016

Sorry, I should have mentioned it is a 1992 200tdi original defender engine

Thanks for the advice James

Saint.V8 it luckily doesnt have an alarm! Thanks for the idea about solenoid, ill look at that too

julianf · Mar 21, 2016

Are the rockers still moving?

Shanec · Mar 21, 2016

Hi Julian,
I have not had a chance to look at anything in detail as had it recovered to parents about 100 miles away. Are you thinking timing belt has snapped?

I found this, but I do not know if my pump is Bosch. Looks straightforward. http://gnarlodious.com/vanagon/bosch_pump/-Rebuild

Saint.V8 · Mar 21, 2016

Both 200 and 300 Tdi's used a Bosch Pump.

julianf · Mar 21, 2016

Shanec said:
Hi Julian,
I have not had a chance to look at anything in detail as had it recovered to parents about 100 miles away. Are you thinking timing belt has snapped?

You said -

Engine cut out suddenly within a split-second without any jerking or spluttering.

Every fuel issue ive ever had has had some warning. Belt failure just turns off the engine, just like that.

Easy enough to tell though - just take the oil filler cap off and look at a rocker, whilst you get someone else to turn the keys to crank the engine.
(this is assuming you can see the rockers through the oil cap - you can on the 300)

300s (generally) survive belt failure well. I assume the 200 does likewise.

Shanec · Mar 21, 2016

Very interesting information about belt. I didn't hear any valves hitting pistons so is the 200 a non interference engine I wonder?

Bosch pump it is then

Will have more info when daylight

jamesmartin · Mar 21, 2016

Shanec said:
Very interesting information about belt. I didn't hear any valves hitting pistons so is the 200 a non interference engine I wonder?

Bosch pump it is then

Will have more info when daylight

all tdis are interference

IamRobbie · Mar 21, 2016

I brought a 200tdi disco with snapped timing belt. Rockers didn't move when cranking and it did survive, 3 years later it's still in my 90 working away after 8 new push rods

mojo247 · Mar 22, 2016

Even with a leaking seal, you should be able to get fuel in and start it. I had a seal replaced on the distributor head on my 300tdi IP but it still worked ok prior to this.

It took a morning by a local diesel pump specialist and cost me £150.

Shanec · Mar 22, 2016

It was a very strange situation - just suddenly cut out. probably internal failure as well as leak.

julianf · Mar 22, 2016

Shanec said:
It was a very strange situation - just suddenly cut out. probably internal failure as well as leak.

So you've checked the rockers now? All ok, I assume...

Diesel Bob is where my pump is going when I get around to it.

Shanec · Mar 22, 2016

Rockers OK, but bought timing kit inc belt tensioner idler gaskets to replace at same time

not sure if I should be buying crank and cam seals but 1 I don't know which ones need, and 2 I don't know if need special tools to get pulleys off.

put an advert for pump, if not will take it off and repair.

julianf · Mar 22, 2016

Ive just done the crank seal on mine, as it was leaking.

Personally, id not bother if its not leaking (i purchased the seal to do the cam, but did not do it).

People seem to have issues with the crank seal, so i figured, if it aint broke....

(but, as i say, mine was)

Ive not done enough miles to know if it was sucessful, but i took my time, and it was obvious why the old one was leaking (crank sprocket moving on crank)

(this is a 300, but its very similar, i believe)

Ive done a belt change on the 300 with borrowed tools, 250 miles from home (belt failure) but much much easier to get one of those kits off ebay - the ones in the red boxes - £24 ish inc delivery.

They come with a pump locking tool too, but, if youre doing the belt, you dont really need to keep the IP position, as youll time it all up again anyhow.

Personally, in your situation, i would send the pump, tomorrow, to somewhere like diesel bob (there are others) and pay for a complete seal set (i think its £180) and recalibration to stock setup. That way you know youre getting a known good unit back, that will last 100,000 miles plus, rather than a 2nd hand that may go tomorrow.

You might get someone to do it as a rush job - send next day wednesday, worked on on thursday, and sent back - delivered friday (or is friday a bank holiay - im not sure)

Shanec · Mar 26, 2016

Today stripped it all down ready for new pump and belt etc

Ordered disco timing kit by accident

Forgot to order pump gasket

So will postpone til next weekend to rebuild.

Going to strip my broken pump and rebuild to learn how it works. I want to fix everything myself .

BTW if anyone is struggling with crank sprocket, jam a breaker bar under driver side chassis rail and crank engine using starter motor.

Easy peasy

Marmaduke · Mar 26, 2016

Shanec said:
Today stripped it all down ready for new pump and belt etc

Ordered disco timing kit by accident

Forgot to order pump gasket

So will postpone til next weekend to rebuild.

Going to strip my broken pump and rebuild to learn how it works. I want to fix everything myself .

BTW if anyone is struggling with crank sprocket, jam a breaker bar under driver side chassis rail and crank engine using starter motor.

Easy peasy

Once you've taken the wire off the fuel solenoid

Shanec · Mar 27, 2016

Why's that?

julianf · Mar 27, 2016

so there's no danger of the engine starting

(not that there is if your pump is knackered)

as per my previous post - its not getting the bolt undone that's so hard - its doing it up to any measurable torque when you are done that is troublesome without locking the crank.

ive had someone stand on the brakes when in gear before, when i had no tool. im not sure how much of a good idea that is, or isnt though.

Defender conked out

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