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Thread: Allroad 2.5 TDi - Not starting.

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  1. Allroad 2.5 TDi - Not starting. 
    #1
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    I have an 1999 Allroad, 2.5 TDi, ( 175*** miles) which won’t start.
    It all stated after I got it stuck in some mud, this may be un-related.
    It got towed out with a tractor, during this it got sudden jolt.

    The journey home was about 1hr, with lights and radio on ect.
    The next day it would not start.

    The AA diagnosed a faulty in tank fuel pump as it would start when the bottom of the tank was hit with a hammer and block of wood. It would only run for a few seconds before it stopped again.
    The local side street garage fitted a new fuel filter and flattened the battery whilst trying to diagnose the why the in tank pump wasn’t working when the ignition was switched on. (see below)
    A new battery was fitted and it started first time, after some spluttering.

    The following day it wouldn’t start again – fuel filter was empty and the pipelines where all dry.
    A mobile auto electrician also diagnosed the in tank fuel pump.
    He removed the electrical plug and pipe on top of the pump and connected a battery directly to the pump which ran but no fuel was being delivered out of the pipe.

    A new pump was fitted and it still would not start.
    At this point I was told by two bits of information by the main dealer,

    1) The main fuel pump on the engine may have failed as they don't like being turned over with no fuel being delivered.

    2) On the 1999 era 2.5Tdi Allroads the in tank fuel pump only transfers the fuel from one side of the tank to the o\s side where the main engine supply is “sucked up” by the pump on the engine.

    Since then I have bleed the fuel system by using a separate 12v fuel pump connected between the fuel filter and the engine supply (clear pipe) which I ran until I could see fuel in the clear pipe.
    After reconnecting the filter to the engine, the fuel injector pipes where been loosened and engine cranked to check fuel is being delivered to the injectors – which it is.
    Injector pipes have been reconnected and it still won’t start.

    My questions are....

    1. Could the jolt from being towed out of the mud upset the stability sensor causing it not to start ?
    2. Or is the main fuel pump dead?
    3. if so what are the error codes?
    4. Anything else I should be checking?
     
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  2. Re: Allroad 2.5 TDi - Not starting. 
    #2
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    Probably, you will need your injection pump to be rebuilt. They don't like to run without diesel on it.
     
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  3. Re: Allroad 2.5 TDi - Not starting. 
    #3
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    In my opinion, this is just an air in the fuel system. When the engine is running the injection pump Sucking the diesel from the tank. When you turn off the engine the vacuum in the system remains. If there is leakage, no fuel is Leaking out but the air enters and the pipe and the filter are emptied of fuel and filled with air.
     
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  4. Re: Allroad 2.5 TDi - Not starting. 
    #4
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    It could be, these pumps are hard to bleed if you don't follow the right procedure.
     
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  5. Re: Allroad 2.5 TDi - Not starting. 
    #5
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    If you are still having problems -
    1) In tank pump only transfers fuel befween the fuel tank sections. It has insufficient power to deliver fuel to the fuel filter. If filter is removed and pipes left open all fuel drains back into tank. YOU WILL THEN FLATTEN THE BATTERY ATTEMPTING TO GET FUEL TO THE FILTER AND PUMP! You MUST clamp off the two hoses to the fuel filter before removing/replacing it.
    2) You are,spot on interms off bleeding the fuel system using the 12volt pump as you described. What you can do is run the 12 volt pump until you see the fuel inclear plastic tube and the start the engine. (Do you notice any fuel seeping from the connections to the fuel filter??? If there are any leaks the 12volt pump will highlight tem by pushing fuel out!)
    3)If engine starts leave the 12volt pump on a further 10 secs and if the fuel pump is working ok the engine will continue to run.
    4) Shuty off engine, clamp off hoses on either side of 12 volt pump before removing. Connect up hoses in final configuration and start engine.
    IF engine starts and continues to run THE FUEL PUMP IS OK.
    Leave car overnight - if it does not start, you have a leak in the fuel hose somewhere from tank to fuel filter - air is getting in an causing the fuel to run back into tank and you are back to no fuel in hoses.
    MIGHT BE AN IDEA TO LEAVE 12VOLT PUMP CONNECTED OVER NIGHT TO SAVE YOU HAVING TO RECONNECT.
    Hope the above helps.
     
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