Hi All,

SOLVED:

The problem was the seals in the pressure regulator on the HP pump. Thanks for the posts and links, TD4 now running sweet as a nut again

I have a problem, (or maybe more) with my Freelander 1. It is a 2005 facelift TD4. Up until the problem it was running fine and with no evidence of an impending failure, but I have been hammering it a bit to/from work (60 miles each way) - set-up is with a Pierberg MAF and Ronbox 2 set at high torque/high pressure (setting 10), and blanked EGR.

I drove home yesterday - 60 miles pretty fast, and when I got to a garage near home it wouldn't re-start - called Greenflag and the only thing he could do was to inject a bit of easystart - his code reader kept failing part way through reading the protocols. The easystart kicked the car into life and it drove home ok. As far as I am aware this is the first time easystart has been used. When it re-started the tickover was smooth at approx 800 revs, but a (little) bit lumpy between 1500 to 2000 revs. (Previously it was fine through the rev range).

I've now got the car home and now it won't start either hot or cold (left overnight) without easystart. I've put the original MAF back and disconnected the RONBOX and same result.

I've checked the LP pump (disconnected at return from HP pump) and it is flowing diesel ok.

I've disconnected each injector in turn when running and it goes lumpy each time so all are injecting fuel (but I haven't tried leakback test yet).

I've connected an iCarsoft i930 (Jag/Landrover specific) and an Autel generic OBDC2 reader and all pressures etc appear to be reading values, HOWEVER, they do not show any faults - even when I disconnect an injector. Does anyone know what pressures or other settings I'd expect to see at tickover and at various rev renges?

So, any hints on where to go next?.

Is it possible I have a hardware fault (injector leaking, sensor etc).

Could I have damaged anything using the RONBOX set on high torque/power and hammering things (eg HP rail pressure sensor / HP fuel pump?).

Could there be something on the engine management system which needs resetting (ie, the reason fault codes don't seem to be registered).

Cheers all.

The high pressure fuel pump has a regulator. Recently another poster on here had a problem with non-starting. Turns out it was the O rings on the regulator. So definitely worth a check on those. They cost under £10 so it's probably best to simply change them anyway.
What is the live data value for the HPFP and LPFP on the I930 at idle?

Excessive injector leak back, or an issue with the pressure regulator/valve on the HPFP can both cause non start issues

Thanks for the replies guys.

I'm having a couple of lazy days at the moment so I haven't checked anything since stripping down to check all sensors. When I put it back together I'll get the info on before/after pressures and other data.

I did see the thread about the HP pump pressure regulator o'ring. Is this easy to get at?

Cheers,

i just cured a similar starting issue by changing the seal in the hp regulator...remove inlet manifold and you can get to the 2 mounting torx screws,i used a socket and a universal joint to undo mine,change seal,backer and gasket(less than 12 quid off ebay)and it started first time.

I decided to be a bit less lazy than normal for a Sunday and had a look at the HP regulator as the manifold etc was already off - as per xamtex and others suggestions. The O'ring has split with a small piece missing, and the PTFE glide ring also has a large gap in it. New seal kit on order and I'll post back if this works.

Pain in the bum to get the torx screws out, but if it works then 10ish quid well spent (not sure how many Euros that is now!!)

Edited to show a couple of photos for anyone else with the same problem. Also, part numbers for the regulator are:
CR / DRV F K / 10 S
0 281 002 480
49013

Search on well known auction site or prime seller using the middle number (spaces not necessary) and you'll get loads of suggestions for the complete part and the seal kit.

Cheers to all for the suggestions.

the ptfe ring comes with a split in it as new.

Thanks, I thought the PTFE ring would be split because it wouldn't stretch over the shaft like the o'ring will.

Got it all sorted - it was the pressure regulator on the HP pump. A bit of a pain to change but now running very sweetly again. Also changed a few of the small fuel hoses (leak off etc) whilt the airpipes and manifold were off as they were showing signs of wear.

Cheers to everyone for help, advice and links.

HI ach2.
Hopefully all is good and the FL is running smooth