Defender 90 TD5 Wouldnt start after fuel filter change

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tilly2

Well-Known Member
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Location
Stafford
My lads just bought a Defender 90, and Ive been putting an ever increasing list of bodges from the previous owner(s) right on it.

We replaced the aux belt, tensioner and roller bearings as it sounded like a bag of spanners. Fired it up, and it sounded lovely. Next item in the big box of parts was the fuel filter. Took off the filter cover plate, (I dont have one on my disco so surprised to see it.) Found a fuel filter housing that was just falling apart, but I removed the filter, and fitted a new one. Now I know I usually fill the filter full of fuel, but I hadnt any spare to hand. Turned on the key and purged the fuel system. Turned the key, and it fired up first time, for about 10 seconds, then dies. Tried purging it for about half an hour but nothing. The pump just kept running and was louder than normal. By then the battery was flat, my fingers were numb from cold, so I stuck the attery on charge and left it for this morning.

First thing this morning, another 30 minutes of purging, and still nothing. Headed off to the local LR suppliers and picked up a new fuel filter assembly, which hit my pocket for £138. I took off the old well past its best unit, and replaced it with a shiny new one. Despite cleaning up the fuel line plugs, they seemed worn and wouldnt snap tight on the brass pipes. I ftted cable ties so they wouldnt pop off mid flight... Turned over the key, after another endless round of purges and still nothing. I was now loosing the will to live...

I fitted my cheapo fuel tester to the fuel regulator, after removing the fuel temperature sensor. Turned it over and a nice healthy 4 bar. I decided to press the purge button on the valve to let off the pressure, and the fuel that was being discharged looked like yellow foam. After about 2 litres of this the fuel ran clear, and the tone of the fuel pump went from a continuous high pitched gurgle, to its normal low noise levels. Turned over the engine but it still wouldn't start. I sprayed a bit of easy start into the snorkel and the engine burst into life, and ran on its own steam. It's now running great again.

Thins I have learnt today about the TD5 fuel system:

Listen to the tone of the pump, it tells you if theres air trapped in the system
Fill the filter full of fuel before fitting
Constant purges just froth up the fuel in the lines. You have to drain that foam out before it will start.
Treat yourself to a cheap Ebay fuel pressure kit. Its been worth its weight in gold. £16 delivered. Yes they do fit the TD5.

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https://www.ebay.co.uk/itm/Universa...639898?hash=item1a84b58b5a:g:K3wAAOSwK1ZdhIQL
 
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Glad you got it sorted. l've always filled the new filter with diesel before fitting it and done a single purge on the system and it's always been fine.
l guess fitting a completely empty filter just introduced too much air into the system.
 
I agree.... we ended to replace the filter housing anyway but never expected to see so much air trapped in the head.
 
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