200TDI Crank, No Start - Investigation Thread

[s8ndst0rm]

Have you tried operating the lift pump by hand?

Yep. Pumping nicely.

 

[Anaconda]

Yep. Pumping nicely.

Good show.
Get the battery charged up and give it a go.
Will be slower to start than normal since you have disturbed everything.

 

[s8ndst0rm]

Whilst I’m waiting for the charger to do its job this morning, I was matching up my fuel pipe routing compared to the video.

I’ve drawn up a diagram which shows the flow.

My fuel is starting into the lift pump rather than into the filter which doesn’t match, and I haven’t (yet) worked out how or if fuel actually returns to the tank or if it just returns to the filter.

Anything look fundamentally screwed here?

Might be useful for understanding the system.

 

[landowner]

Mine went...
tank to lift pump,
lift pump to filter,
filter to fuel pump
pump to injectors
Leak off pipes back to tank

 

[miktdish]

Mine too, your fuel 'path' looks right to me.

Get that battery charged, turnover sounded awful in your vid

 

[Dippypud]

Not turning over very well, might be an earth problem

Poor old bat has been trying for a while now ...

 

[s8ndst0rm]

PROGRESS UPDATE:

 

[s8ndst0rm]

Need to do something about this green wire which is holding on for dear life

 

[Anaconda]

PROGRESS UPDATE:

Well done

 

[dag019]

Need to do something about this green wire which is holding on for dear life

From memory green and brown is for the reverse switch on the back of the gearbox (assuming LT77). So it is not essential for getting or keeping the engine running. Although that doesn’t mean it shouldn’t be repaired!

 

[s8ndst0rm]

Taken it out for a drive this morning. Cooling nicely, no new noises.

Only issue is a slightly higher idle than before. Pretty sure that’s just a screw adjustment. I’ll take a look when I’m wearing my scruffs again.

 

[Anaconda]

Taken it out for a drive this morning. Cooling nicely, no new noises.

Only issue is a slightly higher idle than before. Pretty sure that’s just a screw adjustment. I’ll take a look when I’m wearing my scruffs again.

It is a screw adjustment or might even be the throttle cable itself, which is also adjustable.

 

[dag019]

It is a screw adjustment or might even be the throttle cable itself, which is also adjustable.

I would start with the throttle cable rather than adjusting the pump. I always treat the pump adjustments as the final resort.