New fuel pump problem

This site contains affiliate links for which LandyZone may be compensated if you make a purchase.

slim jim

Active Member
Posts
575
On the first week of January I replaced the fuel pump on a 99 Td5 defender. I've been stuck on the side of the road three times since, the three occasions I had a half tank of fuel left or maybe a little less than half. There is no warning at all like spluttering or normal stuff you would associate with a fuel problem, power just dies and she will not start.
The week before last I had it towed off the motorway and let them bring it to their garage to see if they could find the problem.I picked it up few days later and was told that it was caused by oil wicking through the wiring loom into the ECU (a common Td5 problem).

About ten years ago, I replaced the injector loom because of this. I cant remember the exact symptoms at the time. But it never left me stranded.
This morning on the way to work, she stopped again on the motorway. Same thing a little less than half left in the fuel tank, and I got it towed to my house. I went and bought five liter's of diesel , bled the system, put some brake cleaner into the air filter and she started on the second attempt, drove it to a petrol station, filled it with diesel and she is running grand now.

I forgot to mention that they had pressure tested the system, in the garage last week and they said that it was perfect. Apart from it being very slightly harder on diesel than it was before with the old pump and that the diesel gauge is much more responsive, there is no other obvious difference apart from I cant rely on it anymore.
If anyone can think of what it might be that could be causing this issue please tell me. Thanks for reading such a long post.
Slim Jim
 
So, I assume you are saying it will not restart after it has died on you.

Did you try leaving it 20 minutes to cool down and try again?

Cheers
 
So, I assume you are saying it will not restart after it has died on you.

Did you try leaving it 20 minutes to cool down and try again?

Cheers
Yeah, an hour and a half on the hard shoulder, waiting for a tow, this morning and it would not start again, when the tow truck arrived.
 
Yeah, an hour and a half on the hard shoulder, waiting for a tow, this morning and it would not start again, when the tow truck arrived.

OK, not similar to mine then as mine would restart when cooler, found the CPS was dying.

Silly question, Not empty is it??? Have you checked the tank capacity against miles driven, when I took out my pump and put it back in , I messed up the sender unit , now it only shows max 2/3 tank when full.

Cheers
 
CPS?? Crankshaft position sensor?
No it wasn't empty , it took 45 liters to fill it today and it is a 75 liter tank.
 
110 then ??

Cheers
I was puzzled when I replaced the pump because I could not understand when the tank became half empty , how fuel got to the engine. See diagram.
I have the old pump in a shed and I will look tomorrow to see how diesel got to the bottom of the pump when the tank was less than half full.

Fuel Pump Diagram.jpg
 
I was puzzled when I replaced the pump because I could not understand when the tank became half empty , how fuel got to the engine. See diagram.
I have the old pump in a shed and I will look tomorrow to see how diesel got to the bottom of the pump when the tank was less than half full.

View attachment 142337

Not sure what your point is :), mine was that the sender has a float on it on the D2, which I managed to "adjust". Is it not the same for the Fender?

Cheers
 
Not sure what your point is :), mine was that the sender has a float on it on the D2, which I managed to "adjust". Is it not the same for the Fender?

Cheers
Yeah the defender is the same, I'm not sure if the diesel has a way of getting into the pump after the fuel has dropped lower than the top of the pump.
Maybe I missed some protective package seal that could still be on the pump , I don't know.
Thanks for your help so far.
 
There is a two stage pump within the pump unit, but should always be able to pump from well below top of pump. I used to have lots of fuel problems with various fixes (not had any for a year or so now!) that I could suggest. However you need to prove where the problem is. Ie before or after the fuel pressure regulator. (FPR) If at all possible take it on a run where you can replicate the problem. Disconnect the input fuel line from the FPR and turn on ignition. You should see a steady stream of diesel. If not then suspect the fuel filter or housing.
 
Back
Top