Disco 2 Intermittent Starting Problem (and lack of power)

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sierrafery said:
As about those cruise control fault codes is your cruise control working OK? ...if yes, do you have standard dimension tyres?
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Last time I used cruise control it was fine (have never had a problem with it) and tyres are standard on original 18" alloys from the factory. Trying to get the graphical data - won't be much there but want to have a look while I wait for the fuel pressure test gauge to arrive.
 
I just remembered as well that when I last put fuel in the vehicle (fuel tank level had been 1/4 tank or less for quite a while) several weeks ago when this issue first arose, I had a lot of trouble - bowser kept cutting out. Ultimately I got a new fuel cap and everything was fine for a few weeks, but I'm thinking, is the other breather line that feeds into the fuel filler tube blocked as well? Can I check that perhaps, feed a bit of wire down it from inside the fuel filler pipe, or access it (easily?) from underneath?
 
sierrafery said:
I have no ideea how you could chck the breather system unless it's something visible, rule out that thing i've shown in post #22 cos that can make trouble
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Car is out on the roadside parked. Fairly level spot, so maybe I could jack up the driver's side rear (on roadside rather than impossible to access gutter side), stick in an axle stand and access that breather line (post 22) from underneath? Is it easy to find/access, or a big job requiring a hoist?
 
Okay - update! Need to keep plugging away - determined to fix this problem with my 2003 Disco 2 Td5.

Battling flu and a lingering chest cold, but had a diesel (or hydraulic fluid for that matter) pressure tester (12mm connector to the FPR FT sensor port) made up at Enzed for $80 - couldn't find anything decent anywhere else.

First, checked some potential issues again:

1. Engine oil level still fine and absolutely no detectable diesel smell in oil.
2. Got a free (spare), new genuine L/R air-bleed valve (top of filter housing) - removed old one and put the new one in.

So, before I check the diesel fuel pressure at the FPR, thought I'd prime the fuel system after putting in the air-bleed valve and see if things were any better. Followed diesel fuel purge/prime procedure and engine started straight away. However, very rough running (rocking) and poor (flat) throttle response for a couple of minutes and then she just conked out. Guess it's looking more like the fuel pump as it feels like the engine is fuel starved?

Now, interesting thing or very weird coincidence? Thought I'd try starting just once more, but this time remove the fuel cap (it is a new fuel cap) to see if that made any difference as previously I had a lot of difficulty filling the tank with diesel (air-lock?). Weird thing - the fuel cap flap wouldn't open when I pressed the release button on the dash (tried several times with no success)! Weird coincidence or is my Td5 possessed?

Okay, will try and sort out the fuel cap flap issue and using my pressure gauge to check fuel pressure at FPR. Will also try and check that breather line above the fuel tank that sierrafery mentioned previously?

Saga, but I won't admit defeat just yet!
 
Can someone confirm/correct my understanding please:

The diesel fuel pump has a LP pump - this circuit passes the diesel from the tank through the fuel filter to the pump HP circuit

The diesel then gets pumped by the HP pump directly to the FPR

FPR regulates diesel fuel pressure down to 4 bar

Diesel then goes to 5 injectors and also loops around to fuel cooler and back through fuel filter housing to fuel tank


Now, when I turn the ignition to position II - I hear a humming sound (like I always have?) and I assume that's the fuel pump. I understand the Td5 (15P) engine in the Disco 2 only has the one fuel pump (inside the fuel tank) - THERE IS NO OTHER FUEL PUP/INJECTOR BOOSTER PUMP. So, the LP circuit on the fuel pump must at least be working and that is what I'm hearing; HP circuit may not be working effectively - need to check that pressure at FPR is 4bar?

Any thoughts?
 
Okay, will get that awkward to reach FT sensor out tomorrow and attach my new pressure gauge and see what the pressure is.

Searching here and seen where someone was checking their fuel system for a while and eventually replaced the pump then found out the problem was collapsing intercooler pipes (inside delaminates)?! Didn't have a look at my intercooler pipes (did install and EGR bypass around six months ago). Anyway, will check the pressure first and then go from there.
 
The delaminated turbo pipes would create lack of power under high boost but they have nothing to do with starting and low revs... the fuel pressure measurement is the best move at this stage
 
Okay, see how it goes re pressure check. Reckon the fuel filler flap didn't open because I might have had the key in the ignition?

Reckon I'm getting closer to sorting this issue with your assistance!:)
 
Starting to sound like a blog here! So, had an hour spare today and decided to remove the FT sensor (12mm thread) from the FPR. Well, not readily accessible to say the least - had to stand on a few bricks to reach over and down after removing the acoustic cover and contort my hands. Didn't want to break the electrical clip connector on the FT sensor - of course the clip just had to be upside down (clip on underside) didn't it! Anyway, gentle prying with a long screwdriver eventually did the trick! Had to retreat as Disco out on the roadway and started pouring with rain - getting very wet under the bonnet with horizontal rain. Putting my custom made pressure test gauge on shouldn't be too hard now when I next get an opportunity.

One thing I noticed, was expecting some fuel pressure behind the FT sensor - no fuel came out at all when the sensor was removed. Does the fuel delivery system completely depressurise and diesel run back to the fuel tank overnight?

So, when I get a chance, I will check the pressure at the PRV when pump running (and starting) and then likely pull out the fuel pump if pressure doesn't look good. The pump isn't noisy at all and is original fitment (2003 Disco 2 Td5), but that doesn't mean it doesn't have a problem delivering the correct pressure as I now understand. From what I've seen the pump removal looks relatively straight-forward. I've already pulled the carpet back without removing any interior panels at all - just strong thumbs and only took 5 minutes! I will check the fuel pump when I remove it and see if the two pre-filters look clogged; if they do I will clean them and put the pump back in and see how it goes (pressure test again)? If it's clear I need a new fuel pump then I have in mind a VDO/Siemens from Paddock Spares for 199GBP (351.79AUD) + delivery. Anyone know of any other options? Guess I'll steer clear of Intermotor (Lucas) and any of the very cheap pumps on eBay and especially aliexpress!
 
Intestinalworm said:
So, the LP circuit on the fuel pump must at least be working and that is what I'm hearing; HP circuit may not be working effectively - need to check that pressure at FPR is 4bar?
Click to expand...

Have had this happen on a D2, changed fuel filter and it would not start, checked fuel flow at fpr inlet and it was low , then I changed the pump for a spare checked flow again and it was correct. it started after a purge.

the car seemd to have been running on the LP for a while as it was also a bit sluggish compared to the other one.

Cheers
 
Well, attached pressure gauge. Then went through purge/prime procedure and then tried to start - no good and pressure didn't get over 0 bar the whole time. Did it all over again - same thing; did it for a third and final time - same result. So, engine wouldn't start and no pressure showing at FPR. Maybe the pump has totally failed now?

Will pull out pump tomorrow and have a look - check with multimeter and check filter screens just for my own education.

Maybe I need to check the relay for the pump and/or the fuse?
 
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