BMW 525 engine transfer problem

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tonyyzf

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Hi, my name is Tony, I live in the far north of Scotland, I'm new to this site and was wondering if someone could help me. I've searched the forums looking for the answer but can't seem to find a full explanation.

I've been working in my present job for nearly thirty years, part of my work has been repairing and maintaining land-rovers, i've owned a Range-rover V8 in the past and have fixed various other Discovery's etc for other folk so consider my knowledge of the vehicles to be above average.

However I am now stumped, I was asked to look at a 1997 diesel range-rover fitted with the BMW 2.5 6 cylinder engine, having removed the head we realised the big end in cylinder 4 had gone. Having a BMW 525 car lying there without an mot he decided to fit that engine into the range-rover, having removed both engines and transferred everything needed we replaced the engine, however we didn't change the injector pump or injector No 4.

Having tried to start the engine we realised there was no fuel being pumped from the tank and also that it wasn't getting through the injector pump. After sometime of scratching my head, and other parts, I realised that the injector pump may be coded in some way and the fuel system had locked up.

I have looked at this site and come across mentions of security re-learn for the pump, can someone please explain to me how this can be done or point me to the info.

There is an injector warning light showing on the dash,
Do I need to change the control injector?

Thanks in advance for any help you guys can give me.
 
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You need LR specific diagnostic gear to read the injection ecu and re write the security code into the BECM if it has been lost. This is not uncommon when the battery has been disconected for a while. There is a piece of kit called a sync mate that someone may be kind enough to loan/ hire you.
 
A couple of years ago, my RR 2.5 DSE wouldn't start, no fuel delivery from the filter when switched on, the pump in the tank was shot, new one fitted, & all ok since!:)
 
Just replaced my FIP with a unit from the breakers and the engine fired up first shot. There is no coding in the pump. There is coding in the EDC unit against the BECM and this may be your problem. Did you transfer the engine ECU (or EDC, Electronic Diesel Control)?
 
I didn't transfer the ecu and now I have no chance as the donor car has been scrapped.

The in-tank fuel pump was working before I disconnected the battery to put the battery/starter lead around the back of the head, once we reconnected everything and tried to start it the tank fuel pump has no power and the injector pump won't pass fuel to the injectors.

I have managed to hire a sync mate off Chris Townrow on this site, so hopefully it will correct the BECM.
 
Right, we connected the sync mate, solid blue light, then solid green signifying that the BECM is already sychronised.

Following checks confirmed that when the ignition is turned on the heater plugs work, whilst they are being powered the relay for the in tank fuel pump is triggered, when the the heater plugs time out this relay is released too, however no power is being sent to the in tank fuel pump.

We tried gravity feeding the injector pump, nothing, it tries to take fuel but it is not sending fuel to the injectors.

Questions;- Should we have used the Range-Rovers original injector pump? or am I right in thinking the 525 engines own one should work?
How critical is the crankshaft position sensor air gap? we set it at about .5mm
Does the in tank fuel pump run all the time or just a short while to pressurise the system?
 
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I went through the same process Tony and came to the conclusion that you can't uses 525 pumps, I know many have but I had the same issues as you :(

I'm now re-fitting a range rover one on but have the rebore the BMW engine casing as the range rover pump had a bigger bore than the bmw pump :(

Hope this helps
Dan :)
 
My DSE has an engine from a 525tds BMW (or so I was told when I bought it).
I remember reading somewhere that if your pump model number is 994, than it's a straight swap. If it's 992 or 993 it wouldn't work. Afterwards I checked the number on mine and it's indeed 994. Maybe it's worth a shot to check what's the model number on the pump fitted to that engine and checking for compatibility?
 
I thought the fuel pump only ran whilst the engine was rotating as it needs an input from the alternator.
I got caught out a few weeks ago after I had changed a fuel filter on a P38 diesel without filling it with fuel first before fitting, after assuming that the tank pump would fill it the instant the ignition was turned on and I could bleed the system.
After pulling my hair out, the diesel guys on here enlightened me to my oversight !!!
 
Irish,
I just changed my fuel filter last weekend and apparently I also forgot to fill it with diesel first. But, when you turn the key (position 2 IIRC) the fuel pump runs for a short while (to pressurize the system). I just kept going from position 1 to position 2 and back until all the air bubbles where gone. And then it started just fine :)
So, the lift pump runs for a short while after you turn the key.
 
Just had the guy check the numbers on the pumps, the one fitted to the 525 engine is 995, does anyone know whether or not this should work with the Range-Rover ECU or am I going to have to fit the 994?
 
Well, we finally got to the bottom of the fault, the 525 engine is running in the Range-Rover.

The injection pump from the RR won't fit the 525 engine, the boss size is too big, but...it takes 10 minutes to remove the electric control module from the top of the 525 injection pump and replace it with the one from the original RR pump, the two modules are wired completely different so you need the RR one, the pump bodies however are identical, so ignore the pump numbers. We also changed the injection timing device at the bottom of the pump but aren't sure if that was necessary.

After weeks of head scratching and land-rover specialists telling us the wrong things we finally found the fix through sheer desperation.

The vehicle is running sweet as a nut and goes for MOT tomorrow.

Anybody got any questions feel free to ask while my memory is still fresh on the matter.
 
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Tony,

The pump you were using was a 995, correct ? Did you ever try with a 994 and found out that they also won't work, or did you go straight to replacing the pump's electric control module with the one from the RR?


I've always been interested in this subject since my DSE has an engine from a 525tds. If you could do a general writeup on the difficulties you encontered it would be a great help for anyone else going down this route.
 
The injection pump fitted to the BMW 525 engine which we put in the RR is a 995, this will not communicate with the RR Electric Control Module/ECM or ECU which is fitted beside the battery. The original RR pump, a 994 will not physically fit the 525 engine as the front boss/seal is different.

We didn't have the above mentioned ECM from the BMW car so we eventually changed the top half of the injection pump itself, the electric control unit on top of the pump that communicates with the ECM, we split both pumps and fitted the RR top to the BMW bottom parts and made a pump that fits the 525 engine and communicates with the RR ECM. This is a simple task if done with care, taking around 20-30 minutes.
 
modelman said:
A couple of years ago, my RR 2.5 DSE wouldn't start, no fuel delivery from the filter when switched on, the pump in the tank was shot, new one fitted, & all ok since!:)
Click to expand...
Just replaced my FIP with a unit from the breakers and the engine fired up first shot. There is no coding in the pump. There is coding in the EDC unit against the BECM and this may be your problem. Did you transfer the engine ECU (or EDC, Electronic Diesel Control)?
 
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