L322 L322 2004 RR diesel TD6 no start. FUEL INJECT. SYSTEM message. Air in fuel line.

Dr Veg · Feb 16, 2025

Hi I'm new here...this is my first post.

My 2004 L322 RR TD6 won't start despite healthy cranking.

I let the fuel run low to the 40 miles range message. Then it fails to start and gives the "FUEL INJECT. SYSTEM" message.

I've refilled the tank at home to over half full but still no start.

The secondary inline fuel pump (by rear left wheel) was a bit noisy..buzzing..so I changed it out for a new one. Still no joy and new pump similarly buzzy.

I saw air bubbles in the clear tube that runs from the diesel filter to the high pressure pump. Also if I disconnect that pipe and turn the key I get diesel squirting out of the filter but it does appear to have air in it.

This all makes me think the inline pump is sucking air from the tank or the line from the tank to the inline pump is perforated.

The intank pump runs because I can hear it humming.

Any ideas out there?

kermit_rr · Feb 17, 2025

Possibly the in tank pump isn't working so the pickup side still doesn't have any fuel?

kermit_rr · Feb 17, 2025

How much did you put in, was it the right amount for what shows on the dash?

Dr Veg · Feb 17, 2025

kermit_rr said:
Possibly the in tank pump isn't working so the pickup side still doesn't have any fuel?

Thanks for your reply

I put in 40L of disel and the instrument panel shows the correct level. I also did the test sequence on the instrument panel which shows the individual levels on both sides of the tank and this confirms that the fuel I added got equally distributed to both sides.

Dr Veg · Feb 17, 2025

kermit_rr said:
How much did you put in, was it the right amount for what shows on the dash?

Thanks for your reply

I put in 40L of disel and the instrument panel shows the correct level. I also did the test sequence on the instrument panel which shows the individual levels on both sides of the tank and this confirms that the fuel I added got equally distributed to both sides.

Dr Veg · Feb 17, 2025

One other thing. It tries to fire up when I mist the air intake filter with easy start, though it doesn't catch.

Dr Veg · Feb 17, 2025

Update: The in-tank pump is a gonna! What I though was humming from the in-tank pump was possibly just vibration transferred either from the in-line pump or possibly the air suspension compressor. I've removed all the carpet etc. to get to the tank access panels and when I listen where the pump is (RHS) there's nothing when I turn the key.

I've pulled out the pump assembly and tested it on the bench with a car battery to the pump +/- terminals and it does nothing....well, sometimes just a clunk. So I'm going to replace that assembly and hopefully that's it.

No problem disconnecting the pipe thing that runs from the LHS of the tank to the pump assembly but getting it reconnected looks like a b@**tard without sinking my arm into a tank full of diesel from the LHS access opening.

Will let you know.

Dr Veg · Feb 26, 2025

I changed out the in-tank pump and the sender unit on the LHS of the tank. What a lovely job that is - I'll be smelling of diesel for weeks. Range rover designers have got a lot to answer for!

HOWEVER, it still doesn't start and I continue to see air bubbles in the clear tube that sends diesel out from the fuel filter. The secondary low pressure pump is buzzing when it starts up which suggests it's still pulling air in from somewhere.

Anyone got any ideas about the fuel line(s)? that run from the in-tank pump to the secondary pump - I guess there could be an air leak somewhere in the line although I don't see any fuel leaks. I'm a bit perplexed TBH.

Any help out there would be much appreciated.

Dr Veg · Mar 17, 2025

So I find that no fuel is coming out of the pump out hose (blue) though the pump is running. Somewhat unbelievably, the new in-tank fuel pump assembly I fitted is defective. I took it all out again and I saw that the fuel delivery pipe inside the unit is broken off of the electric pump itself, which explains why fuel was not being pumped out of the tank to the secondary pump. I'm expecting the supplier to replace it. Hopefully that should arrive in a few days!

Blob · Mar 20, 2025

That's some saga and sadly too true too often with eh quality of parts these days.

I had a BMW 525TDS many many years ago that had an in tank pump failure in the middle of a junction directly outside a BMW showroom, could never decide which was funnier, the salesman trying to direct potential customers away from the window or me getting the opportunity to wheel out the old "tell you what, I'll sit in your car and press the horn while you sit in mine and try to start it!" to the idiot behind me. Best part was he replied "I've been following you for ages and it was fine"
"Well yes mate it was actually a bit of a surprise to me when it stopped there!"

Anyway, the point of all that was that when the RAC turned up, the tech told me that sometimes you can reverse the polarity on the motor and it will free off, we decided to try and it did! The pump worked fine to get me home and then I replaced it.

At least it seems you've got to the source of your issue (or at least the first one), hope it's all smooth sailing from here.

Dr Veg · Mar 25, 2025

Changed the in-tank pump. Checked it's working - delivers fuel out of the 'out' line when turned on. However, still no cigar...still same message on dash "FUEL INJECT SYSTEM" and I still hear the secondary pump (new) buzzing as if it's pulling in air. Strange. The old pump was definitely broke so I'm a bit mystified as to why the new pump has not solved the problem. Not sure where to go from here.

Datatek · Mar 25, 2025

Dr Veg said:
Changed the in-tank pump. Checked it's working - delivers fuel out of the 'out' line when turned on. However, still no cigar...still same message on dash "FUEL INJECT SYSTEM" and I still hear the secondary pump (new) buzzing as if it's pulling in air. Strange. The old pump was definitely broke so I'm a bit mystified as to why the new pump has not solved the problem. Not sure where to go from here.

An echo

RangeRoller dt · Mar 25, 2025

Fuel pressure regulator seal is known to give up.

Dr Veg · Mar 25, 2025

Is that on the high pressure rail ?

How do I get to it ?

RangeRoller dt · Mar 25, 2025

round thing on the end of the rail. See if this sounds familiar

L322 TD6 Fuel problem

Hi all, firstly the car was running fine then just stopped. A mechanic came out and said there is not enough fuel pressure getting to the engine. So fuel tank filters have been cleaned and also checked the pump inside the tank which is fine, I also replaced lift pump under rear passenger seat. I...

www.landyzone.co.uk

backinblack · Mar 25, 2025

Datatek said:
An echo

Yep, just replied on other thread. Multiple threads for the same thing doesn't make it easy.

Dr Veg · Mar 26, 2025

backinblack said:
Yep, just replied on other thread. Multiple threads for the same thing doesn't make it easy.

Sorry guys.

L322 L322 2004 RR diesel TD6 no start. FUEL INJECT. SYSTEM message. Air in fuel line.

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