Disco 300TDi Fuel Injection Pump not delivering

Have a 1996 300TDi Discovery, 172 k miles. It trundles along with a few clunks and rattles and still provides the odd shot of adrenaline on corners.
Problem last week - Would start cold but would not start when hot.
Replaced what I thought was a faulty lift pump. Was starting ok from cold
but will not now start when cold or hot - no fuel being delivered to injectors. Plenty of fuel to pump. Bled and re-bled filter / feed / return, etc.
Injector pump is Bosch R509 (Non Electronic Diesel Control).
Any thoughts or leads ?

Red Paddy said:

Have a 1996 300TDi Discovery, 172 k miles. It trundles along with a few clunks and rattles and still provides the odd shot of adrenaline on corners.
Problem last week - Would start cold but would not start when hot.
Replaced what I thought was a faulty lift pump. Was starting ok from cold
but will not now start when cold or hot - no fuel being delivered to injectors. Plenty of fuel to pump. Bled and re-bled filter / feed / return, etc.
Injector pump is Bosch R509 (Non Electronic Diesel Control).
Any thoughts or leads ?

Click to expand...

fuel stop solonoid

Ratty,
You Genius !! your succinct reply 'fuel stop solenoid' cleared the diesel fumes from a befuddled brain ... so I went after the solenoid ...
Turned out it was a faulty DDS (Digital Diesel Shut-off valve), made up of lots of electronic bits in a plastic unit that sits over the solenoid valve. While on-board drilling out 2 shear-bolts holding the DDS (during which I destroyed the DDS as the drill drifted), I got to thinking - why all the electronics and why shear bolts ? .... then the penny dropped - it's an anti-theft device.
Solution - get rid of DDS and route live wire direct to solenoid ... seems to be a runner.

Red Paddy said:

Ratty,
You Genius !! your succinct reply 'fuel stop solenoid' cleared the diesel fumes from a befuddled brain ... so I went after the solenoid ...
Turned out it was a faulty DDS (Digital Diesel Shut-off valve), made up of lots of electronic bits in a plastic unit that sits over the solenoid valve. While on-board drilling out 2 shear-bolts holding the DDS (during which I destroyed the DDS as the drill drifted), I got to thinking - why all the electronics and why shear bolts ? .... then the penny dropped - it's an anti-theft device.
Solution - get rid of DDS and route live wire direct to solenoid ... seems to be a runner.

Click to expand...

Haha. Glad it helped.

Hi Guys
Could this be the problem with mine,1997 300TDI Manual Hot start fault,it has the black plastic box on the side of the injector pump with three wires going into it,I think one wire for the solenoid but what are the other two wires for,is it just a cover or are there electronic bits inside the plastic box.
Cheers
Taza

is that cover on top of where the throttle goes through? If it is its for the EGR system.

The stop solenoid of more to the back of the pump.

The black DDS box is on the back of the pump,fastened on with aniti tamper screws, the drill will be out this weekend.

Cheers

thanks for this thread guys..... i am going to try this out tomorrow.... coz i am having the same problem......
cheers

Hi guys just found your post. I have a 300tdi commercial that i bought knowing it needed love.

She was a running but was starting slow. Ive changed glow plugs, lift pump etc now it will not start at all. All signs point to stop solenoid. I have the black box with 3 wires going into it. I hope i can get a drill in there to get the abti tamper off.my question is would it suddenly die? I moved it to put decat on and then it jhst woukdnt restart.

Heres my original post that didnt go up for some reason:

Hi guys just getting a second opinion. Got a 300tdi commercial that im building. Was running fine the other day so i moved it to do some bodywork on it, went to start it back up wouldnt fire. It hadnt been serviced in a long while before i bought it so i changed the glow plugs, lift pump and gave it full service. It still wont fire but it wants to. Its like its getting no fuel but fuel is coming out when i crack the injectors.
Anyone thinking stop solenoid?? Also how i get to it? Am i right in thinking its under the black cover with 3 wires on injector pump with anti tamper screws?

Any insight would be appreciated