TD5 fuelling issues

Morning All, first post, but I've been gleaning plenty of info over the last couple of years and hoping for more!

We've got a 1998 TD5 defender giving us some troubles. It all started when it wouldn't start and we knew already the pump was noisy in the tank. After doing many things listed below we still have trouble and hope someone can help!

Replaced crank sensor - was the original problem
Replaced fuel filter
Replaced injector seals
Replaced pump in tank
Replaced and installed air bleed valve and nonreturn valve at filter housing
Replaced fuel pressure regulator

Not much left to do really is there? It will start with a small amount of sniff like a rocket, runs and drives well too with no other obvious symptoms. Will probably start with the five throttle pump routine but gave up on that tbh cos its not the answer at the end of the day.
What about the filter housing?
What about getting the injectors tested? Nobody local (Hastings, Sussex) that I know of that can test them.

Any advice appreciated.
Ben

Hello farmerben, best bet is to head yourself over to the Introduce Yourself section first before asking any questions. We likes new people to do that

Silly question, is there fuel in the tank?

I'd head over to the introduction section and introduce yourself first before anything else.

Southernlandy said:

Silly question, is there fuel in the tank?

I'd head over to the introduction section and introduce yourself first before anything else.

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Yep, loads of fuel! Just off to the intro section.
Thanks chaps

I've had a call back from an injector company and thought I would relay what I was told.

He expected injectors to see more than 150k miles before they give serious grief and that it was more likely that the injector seals were still to blame. Much tutting ensued when I told him we used britpart seals as they probably weren't quite to spec and suggested we try genuine seals.

Kent injectors, nice bloke and helpful. Suggested injectors may cost £35-40 each for testing but would have to be sent away.

Farmerben said:

I've had a call back from an injector company and thought I would relay what I was told.

He expected injectors to see more than 150k miles before they give serious grief and that it was more likely that the injector seals were still to blame. Much tutting ensued when I told him we used britpart seals as they probably weren't quite to spec and suggested we try genuine seals.

Kent injectors, nice bloke and helpful. Suggested injectors may cost £35-40 each for testing but would have to be sent away.

Click to expand...

the britpart washers are known to be poor, use genuine seals and washers, and make sure the seats are really clean prior to refitting

johnlad said:

the britpart washers are known to be poor, use genuine seals and washers, and make sure the seats are really clean prior to refitting

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What Johnlad said.^^^^

Quite a few peeps have been aught out by either lesser quality washers or the seats not being clean enough.

Thanks for the comments chaps. We have now installed new original washers and seals and no go.

It runs fine it's just getting it to run in the first place!
We have installed a clear pipe on the return from the fuel cooler and there is no air visible either when pumping, cranking or running.
It does sort of fire once maybe on a crank but not enough to start it.

The only other issue I have found is a crack in the insulation approx half inch from the crank sensor. Could that be it? It is a new crank sensor btw.

Would I be right in assuming that the signal may be strong enough when running and starting with sniff but not good enough to start?
Edit to ask: would this throw an error code? I am a bit skeptical because I was told the injectors may need reprogramming even if they weren't mixed up which I doubt because that would make replacing the inj loom a lot of hassle?
Many thanks

Farmerben said:

Thanks for the comments chaps. We have now installed new original washers and seals and no go.

It runs fine it's just getting it to run in the first place!
We have installed a clear pipe on the return from the fuel cooler and there is no air visible either when pumping, cranking or running.
It does sort of fire once maybe on a crank but not enough to start it.

The only other issue I have found is a crack in the insulation approx half inch from the crank sensor. Could that be it? It is a new crank sensor btw.

Would I be right in assuming that the signal may be strong enough when running and starting with sniff but not good enough to start?
Edit to ask: would this throw an error code? I am a bit skeptical because I was told the injectors may need reprogramming even if they weren't mixed up which I doubt because that would make replacing the inj loom a lot of hassle?
Many thanks

Click to expand...

Something worth checking is that the wires aren't breaking near the ecu plugs under the drivers seat. I've had to solder and heat shrink a couple of wires, one of which was the crank sensor wire.

Crank sensor is one of the only sensors on the TD5 that can stop it from starting, any wiring faults or damage to the sensor can cause it to turn over for ages before firing up

Update: New starter motor sorted the problem. Starts fine.