It's quite common for a pump which is on it's way out to completely fail when the pressure is released at the FPR and air gets into the system cos untill then it could still start on residual pressure but once that pressure is out the pump can't start again... i've seen this not once, don't struggle anymore, put in a new pump and IMO your problem will be fixed... just confirm, did you hear the pump while it was on purge sequence? ... if not the simplest way to rule out the feed is to check for voltage in the pump's plug across the white/purple - black wires in the first 2 minutes after the ignition was turned on, if you have voltage you can replace the pump without remorse

Intestinalworm said:

Have watched a bit on Youtube and www.discovery2.co.uk. Are you able to tell me where this video is - keen to have a look; like to research and prepare as much as possible before I do anything!

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This is the first of THREE.


part 3 iirc is checking the fuel pump.

Cheers

sierrafery said:

It's quite common for a pump which is on it's way out to completely fail when the pressure is released at the FPR and air gets into the system cos untill then it could still start on residual pressure but once that pressure is out the pump can't start again... i've seen this not once, don't struggle anymore, put in a new pump and IMO your problem will be fixed... just confirm, did you hear the pump while it was on purge sequence? ... if not the simplest way to rule out the feed is to check for voltage in the pump's plug across the white/purple - black wires in the first 2 minutes after the ignition was turned on, if you have voltage you can replace the pump without remorse

Click to expand...

Well, Td5 Disco 2 running extremely well for a few weeks now. Received and installed a VDO fuel pump from Paddocks. Reckon I had likely been starting on "residual fuel pressure" for a while! Once I removed the FT sensor at the FPR and installed the pressure test gauge (had one made up at Enzed - pity I won't use it again - it's custom made for diesel fuel pump testing!) there was no pressure on the gauge at all and no starting at all! The fuel pump installation went swimmingly (not in diesel!) - just took my time carefully removing the clips on the four fuel lines (although the new pump comes with clips) - the www.discovery2.co.uk website had a great description. The pump didn't come with a rubber seal, but I cleaned and carefully checked my original seal and it was good as new; just put the seal on the new pump first and then moved it carefully into place in the recess on the fuel tank just before I held the pump down and screwed down the retainer. Went through the purge procedure twice following installation, only time I heard the pump was during the purge sequence as the air was expelled from the fuel lines - now it's all whisper quite!

Just out of interest, I still have the original fuel pump I removed from the Disco 2 Td5. I was wondering if anyone has ever removed the level sensor unit from the plastic pump? Guess I could keep it as a spare? Pump looks in good nick, but obviously the pump motor can't be easily replaced (looks like people just bin the old pump)? Anything salvageable, or just bin it? Hate throwing stuff away!

The level sender is replaceable and you can keep it, undo the wires and the fixing then you can keep it as spare, it's not cheap if you have to buy it, google out YAD500040

sierrafery said:

The level sender is replaceable and you can keep it, undo the wires and the fixing then you can keep it as spare, it's not cheap if you have to buy it, google out YAD500040

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Thanks, will keep it then. Wires disconnected, looks like the unit is held on to the body with plastic clips - hopefully I can just lever it off with a flat-blade screwdriver without breaking any of the clips?

I dont know as i didnt remove one myself, tell me how you managed if you do at least we'll know for the future

sierrafery said:

I dont know as i didnt remove one myself, tell me how you managed if you do at least we'll know for the future

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Should be able to remove given you can fit a new one? Did notice them for sale - checked the sender unit part number you gave me - pricey! Will take care and see if I can get it off - just mindful of old plastic breaking, though the diesel doesn't seem to have harmed the plastic pump in any way; UV exposure certainly makes plastic brittle but diesel doesn't seem to cause any problems from what I've seen (the fuel tank is HDPE I think, maybe the pump body is also HDPE)?

You can repair the pump and it will be cheaper than the whole unit as you dont pay the casing too which you say is in good shape... there are cheaper versions too but if you want the good one this is it: https://www.ebay.co.uk/itm/VDO-Fuel...999266&hash=item59073104ab:g:ogAAAOSwWE9bO4XW