Engine cutting out!

Disco 1 300Tdi Auto 97 is periodically cutting out, just as if the ignition has been switched off. I then can't get it going again for what seems ages. I know this subject has been covered before and I have trawled the search facility and taken on board that it may be the spider that's at fault and that in fact my disco may not have a spider with being a 97 auto, but I have something happening when I switch the ignition on that I've not heard before and wondered if any of you clever chaps can shine any light on it.

When I turn the ignition on with the bonnet up, I can hear a very distinct crackling, like electric crackles and fizzes and it appears to be coming from the injection pump. You can still even hear it when the engine is started. The odd thing is though that before you start the engine, if I put my fingers onto the fuel pipe that goes from the top of the fuel filter and to the injection pump, you can feel this crackling vibrating through the pipe.

The main questions are, has anyone any idea what the hell this crackling may be and if so, would it be likely to be causing the engine cut outs I'm experiencing?

Thanks in anticipation of any replies.

Dunno how or why, but a mates and his 300Tdi auto had an issue with the glow plug wiring. The (usually yellow) loops just below the injectors, whereby one was broken and it was sparking against the head or anything that touched it! He had issues with his main earth to the battery too, only fixed by replacing it and the plug wiring.

Thanks for the reply Paul. I will see if I can spot a problem on the glow plugs. The only thing that makes me doubt this is that, doesn't the power stop to the glow plugs once the engine has started? I'm hearing this crackling even after the engine is started, but in for a penny in for a pound I'll look at any possibilities!

Probably .. My guess is that it was more an earthing problem, the two issues very likely concurrent.

I have now had chance to check the earth strap on the battery and the leads to the glow plugs and the problem is still with me.

I took the car to my local mechanic this morning and he says the crackling is definitely coming from inside the injection pump and that it is no doubt an electrical valve inside it that is faulty. He did say that they can be reconditioned, but I'm not sure I am happy with that with a part that is so critical to the cars operation. I asked him if this could be what is making the car cut out and he said yes because it's all linked into the ECU and alarm/immobiliser system.

One thing I need to know first of all is, if I were to buy a new pump, are they coded at all to marry up with the ECU and alarm.

Secondly, Is there anyone out there that would agree or disagree with what my mechanic has told me.

Pulling my hair out over this because he says that if I have to get a new pump we are looking at it costing close to £1000 to buy and fit it.

Even though there are no warning lights on on my dash, would a Hawkeye maybe pick the problem up?

Any suggestions would be really appreciated!

My 98 D1 300 auto has exactly the same noise coming
from the injector pump, but no issues regarding cutting out.

Stonesinboots said:

My 98 D1 300 auto has exactly the same noise coming
from the injector pump, but no issues regarding cutting out.

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Stonesinboots thanks for the reply. That has made me feel slightly better about things would you believe. I couldn't understand why it runs beautifully even with the noise there. It's the cutting out that I'm stumped on. The noise, I can put up with as long as its not a sign of an imminent fault.

Is it easy I wonder to disconnect the immobiliser? I can't be dead sure, but I'm assuming the fault is electrical and that the immobiliser is the culprit because for no apparent reason my alarm will activate. I've had to unplug the alarm trumpet because of it!.

Toad said:

Stonesinboots thanks for the reply. That has made me feel slightly better about things would you believe. I couldn't understand why it runs beautifully even with the noise there. It's the cutting out that I'm stumped on. The noise, I can put up with as long as its not a sign of an imminent fault.

Is it easy I wonder to disconnect the immobiliser? I can't be dead sure, but I'm assuming the fault is electrical and that the immobiliser is the culprit because for no apparent reason my alarm will activate. I've had to unplug the alarm trumpet because of it!.

Click to expand...

Could be as simple as a dodgy ignition switch.

Or a dodgy stop solenoid? Isn't the stop solenoid connected to the immobizer? I could be wrong about that but may be worth a check!
My 300tdi auto kept cutting out...usually on the motorway at speed, what fun that was! I basically clean or replaced items on the fuel system..sedimentor, fuel filter, stop solenoid etc and it seemed to work!

flat cap andy said:

Or a dodgy stop solenoid? Isn't the stop solenoid connected to the immobizer? I could be wrong about that but may be worth a check!
My 300tdi auto kept cutting out...usually on the motorway at speed, what fun that was! I basically clean or replaced items on the fuel system..sedimentor, fuel filter, stop solenoid etc and it seemed to work!

Click to expand...

Thanks for the reply. I have decided to go through the same process. I don't believe the injection pump itself is my problem. When she is running, she runs beautifully.

I started with the glow plug wires and found 3 of the 4 not tightened up properly. I've had the battery earth lead off and cleaned it all up. Had the little wire off what I think is the stop solenoid, at the back end of the injection pump and cleaned that up. Changed the fuel pump and put some diesel cleaner in my tank, changed the oil and filter and re-connected my alarm trumpet, and so far touch wood the alarm hasn't gone off.

I also locked the doors with the key and then opened them up again using the key fob in case that has anything to do with it. Just waiting to see now!

I had a similar problem where randomly mine just wouldn't fire up, just turning over and over. It turned out to be the shut off solenoid. It's easy enough to test (Although its a bugger to change)



The solenoid is the thing that looks like a spark plug with the blue collar on. To test it remove the wire that attaches to it and switch the ignition on. Then touch the wire back to the top of the solenoid and you should hear a distinct click as it activates. If not then it's seized and that's your problem. They cost about £8-£10 new but as I said above they're a bastard to change as it's nigh on impossible to get a spanner on to undo or tighten up.

Forgot to say, check you're actually getting a voltage to the solenoid when the ignition is on as well.

Critical Mick said:

I had a similar problem where randomly mine just wouldn't fire up, just turning over and over. It turned out to be the shut off solenoid. It's easy enough to test (Although its a bugger to change)

The solenoid is the thing that looks like a spark plug with the blue collar on. To test it remove the wire that attaches to it and switch the ignition on. Then touch the wire back to the top of the solenoid and you should hear a distinct click as it activates. If not then it's seized and that's your problem. They cost about £8-£10 new but as I said above they're a bastard to change as it's nigh on impossible to get a spanner on to undo or tighten up.

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Thanks for the great reply Mick, I am currently running the car and since I've done the things I've listed above, things seem to be good. The alarm isn't going off anymore and it's starting 1st time, instead of having to turn it over and over before it spluttered into life.

Should I find things going wrong again then I will be coming back to your post and taking the advice given. I'm not sure to be honest what it is that I've done to apparently improve things, but I'm certainly hoping it's not temporary!

Well I find it difficult to come on here and admit to what a plonker I am. At long last I got to the bottom of my cutting out. It's one of the first things I should have checked. The flamin sedimentor. I had covered absolutely everything else and drawn blanks, an then the penny dropped. I managed to get the sedimentor undone and found it half full of like a dark brown jelly and some of this jelly was floating in the top of the diesel and obviously blocking the fuel line. I could really kick myself. I've not had a problem since doing it and the car is noticeably running better. I am now a happy chappy!