200 TDi won't switch off!!!!

OK, so this morning I switched engine off and removed key and engine shut down about 1/2 a second after I removed key. Didn't think anything of it. On way home tonight, stopped at Sainsbury's at Colton Top as diesel is only 97.9 there, approached pump, stopped, turned key, removed it, about to open door and she's still purring away. Stalled engine, filled up and came home.

Done some basic diagnostics and chatted to someone who knows a bit about TDi engines. When running with key removed, disconnected negative terminal, still runs. Disconnected positive (after a few sparks) and still running, only way to stop is to stall it. So, conclusion is this:

1. Knackered header spring in main injector pump which fails in the open position, so switching off lift pump with key will still let it run at tickover.

2. Seriously goosed electrics with some major short somewhere not switching pump off when ignition key is turned to off position.

Some observations, barrel is worn as you can remove key in any position, so could be a ferked barrel. Has been down on top end power since I got it, and a did have a niggling doubt in the back of me mind about worn pumps etc.

Got to go to Powerline in Shipley at some point next week to drop a cheque off for a mate who had his injector pump rebuilt by them last week, and they can put the header spring out of his knackered pump into mine and do some diagnostics for £50 (could be £400 for a recon pump though). Or do I waste another weekend trying to chase wiring to find the faults, or send it a local Autoelectrics place and get new looms fitted fer a few hundred quid as well?

Advice greatly appreciated as I don't wanna dig into me savings

can you have a look at the electrics behind the barrel and try to over ride it? see if turning the key actually does anything.

mine was being queer a few months back, when i braked the engine stopped! then when i put it in reverse the engine cut out!

might be worth a look.

surely if its acting normally on tick over i shouldnt be much to do with the pumps. not that i know anything though, you lot got far more exp than me!

G

If it carries on running when you pull the wire off the stop solenoid,then sorry but the pump is bu--ered.Usually its caused by water or dirt or both going through the pump.The hard facing breaks up on the working surfaces of the pump,the swarf moves around and is attracted to the stop solenoid,jamming the plunger.The electromagnet is strong enough to lift the plunger,but the return spring is weaker and cant push it back down - hence it wont stop.

Cheers 8, thats the jist of what I got from the "experts". 170k is hardly worth complaining about for a pump though is it...

170 K - hell I'd be after warranty ! Seriously tho it should have/would have done alot more with clean fuel,3-400 k for a pump,maybe have the injectors done a couple of times.

Reet, got a few phone calls to make tomorrow. Will let you know the outcome, but £50 for powerline to have a look while i wait is nothing in the grand scheme of things. Will let you know the result...

Why don't you just fit a new stopper solenoid?

That's what wrong - it isn't shutting off the fuel.

The test is to start the engine with the bonnet up, then pull the lead off the stopper solenoid. It should stop.

If not, lift it out carefully (look out for the little bit in the middle that usually falls out) and clean it carefully. If the wee plunger thing was stuck, there's your problem.

If it isn't stuck after you clean it you may have a fix.

Make sure the soft tip of the wee plunger thing hasn't broken up.

CharlesY

Reet then, I had a tentative prod around ahead of having a go at it tomorrow, jiggled wires in barrel lock and jiggled about around the injector pump and it now is working (well stopping) again.

So, it coulda bin some muck, or some dodgy lectrickery. Need a new barrel anyhows as you can take key out in any position and even start it with a suitable long thin piece of metal

It will prolly happen again, so as a safety measure will be cleaning and checking things over the weekend anyhow.

what did i say ignore the novice, thats right.

Griffdowg said:

what did i say ignore the novice, thats right.

Click to expand...

Well, I decided that is a wee bit cheaper than paying someone to dismantle me pump and do that sharp intake of breath thing after they know they've fixed it by jiggling it around