Disco 1 Disco 1 300tdi starting issues

Good evening gentlemen,

Sorry if this is a repost, I have been scouring google and different forums but can't quite find someone with the same symptoms as my newly acquired Disco 1.

I just bought a 97 Disco 1 300tdi from a colleague of mine. He informed me when I came to have a look at it that it failed to start a few months ago, and he hasn't been trying since... However, when I turned the key it fired up immediatley, only to for it to die after a few seconds. I tried again and again, and the engine would turn but it just wouldn't start. The last few days I have been trying to figure out the cause of this, checking all the fuses and refilling fuel in case it was low when parked. Today I unscrewed the bleed screw on the fuel filter, and I could see diesel and airbubbles seeping out of it. Tried starting, nothing. Unscrewed it again and tried turning the engine a few turns, didn't look like there was any diesel coming out. Was the engine getting fuel at all? Loosened the banjo bolt and turned the engine, and diesel came pouring out but not at high pressure as I have seen on YouTube and forums. Tightened it back up and tried to start it again and now it started! But again, for only about few seconds...

So my immediate thought is that the fuel pump in the tank must be the cause here, should I be able to hear it when it is working? I read on some forum that the lift pump on these engines is powerful enough to get the engine running even if the pump in the tank is defective, is this true?
Other possible explanations is that the immobiliser is active, but there are no indications on the dash that it is active, and I am pretty sure I heard the stop solenoid clicking when reconnecting the battery. And if the immobiliser was active, would I get it running at all even for a few seconds?

Thanks in advance for any advice!

Auto or manual?

NorwegianDisco said:

Good evening gentlemen,

Sorry if this is a repost, I have been scouring google and different forums but can't quite find someone with the same symptoms as my newly acquired Disco 1.

I just bought a 97 Disco 1 300tdi from a colleague of mine. He informed me when I came to have a look at it that it failed to start a few months ago, and he hasn't been trying since... However, when I turned the key it fired up immediatley, only to for it to die after a few seconds. I tried again and again, and the engine would turn but it just wouldn't start. The last few days I have been trying to figure out the cause of this, checking all the fuses and refilling fuel in case it was low when parked. Today I unscrewed the bleed screw on the fuel filter, and I could see diesel and airbubbles seeping out of it. Tried starting, nothing. Unscrewed it again and tried turning the engine a few turns, didn't look like there was any diesel coming out. Was the engine getting fuel at all? Loosened the banjo bolt and turned the engine, and diesel came pouring out but not at high pressure as I have seen on YouTube and forums. Tightened it back up and tried to start it again and now it started! But again, for only about few seconds...

So my immediate thought is that the fuel pump in the tank must be the cause here, should I be able to hear it when it is working? I read on some forum that the lift pump on these engines is powerful enough to get the engine running even if the pump in the tank is defective, is this true?
Other possible explanations is that the immobiliser is active, but there are no indications on the dash that it is active, and I am pretty sure I heard the stop solenoid clicking when reconnecting the battery. And if the immobiliser was active, would I get it running at all even for a few seconds?

Thanks in advance for any advice!

Click to expand...

Is it an edc engine, if it's not, the following applies.
A non edc 300 Tdi does not have an "in the tank" fuel pump, only a mechanical lift pump on the rhs of the engine block.
Its possibly is an air leak in the fuel system, but the primary filter/sedimenter above the rear axle sort of behind the right rear wheel could be blocked, it has a drain screw but it's plastic so usually breaks,you can remove the sediment bowl but needs care replacing to a lid air leaks, start from the tank check all fuel Iines/joints tank to engine for cracking or abrasion. Disconnect the inlet fuel line to the filter and use the priming lever on the lift pump to manually pump fuel to that point. If the fuel filter on the firewall is not blinded by dirt, water etc the fuel should pump to the injection pump fuel stop solenoid, to check the solenoid listen by the IP as the ignition key is turned on for a distinct click, also check the electrical connection of the wire to the solenoid, it can become loose and not connect well.
Loosen by say half to one turn the flare nuts on all four injectors at the head, turn the engine over on the starter until diesel sprays out at each nut tighten each flare nut the engine should start to fire up gaining momentum as each cylinder comes on line.
To run your diesel needs, compression, fuel and air, check if the intercooler hoses are delaminated or the air filter obstructed.

Thanks for the tips, highly appreciated!
My car is a manual, and I have 3 wires on the fuel stop solenoid with the tamper-proof cover. From what I have read on forums this means I have EDC or DDS? When I was bleeding the fuel lines I tried finding the priming lever on the pump, but could not find it, are these fitted on the EDC/DDS engines also?

NorwegianDisco said:

Thanks for the tips, highly appreciated!
My car is a manual, and I have 3 wires on the fuel stop solenoid with the tamper-proof cover. From what I have read on forums this means I have EDC or DDS? When I was bleeding the fuel lines I tried finding the priming lever on the pump, but could not find it, are these fitted on the EDC/DDS engines also?

Click to expand...

I can't imagine why the edc engine would be any different in the lift pump area.
The priming lever is generally clipped in a vertical orientation below and to the side of the lift pump, if you can feel it pull it up towards the horizontal, if the pump is on the top of the cam lobe you may need to rotate the engine to get the pump on the back of the cam to allow the prime lever to operate.

Found the lift pump handle, thank you very much Gazbo. Felt like an idiot for missing it earlier Loosened the bleeding screw and started pumping, nothing but air came out. I then loosened the banjo bolt and started pumping, out came basically a jacuzzi of diesel and air. So obviously I have an air leak somewhere on the fuel line between the tank and the filter. I have been trying to locate the leak, but I can't seem to find it. Any tell tale signs to look for? Thanks again Gazbo for pointing me in the right direction.

Found it! It was a pinhole on the sender, between the tank and the fuel line. Had to improvise a temporary fix until I can fix it in my garage. Some tape and a ziptie seems to work perfectly for now. She purrs like a kitten Thanks so much guys for giving me the necessary directions!