Hi,

I have a starting issue on my "new to me" 03 Voyager 2.5l diesel

It turns over lovely, but won't fire.
A tiny spray of easy start and it starts fine.
Once started it runs lovely.

Any suggestion where I should start looking?

Many thanks

 

Start by eliminating the low pressure fuel system - lift bonnet, find the hand primer pump it should be hard, pump it, if it takes more than one pump to make it rock hard and impossible to pump any harder you have a low pressure fuel problem. Check the (1) spin-diesel filter is not loose and the (2) screw on water trap is not loose.

If the hand primer needs pumping you are leaking pressure out or allowing air into your low pressure fuel supply, the most obvious are the two I've suggested, either of which will lead to a car not starting warm or cold.

NOTE : The picture of the filter & water trap is for the 2.8 CRD and the hand primer is for a Ford so both are for illustration and recognition purposes only.

 

Thanks for that, I will check it out tomorrow and let you know what I find.

Two other things, When the ignition is turned on I can hear the pump in the tank working away for 4-5 seconds, is this normal?

I just done the key dance and came up with
P0100 MAF SENSOR CIRCUIT INSUFFICIENT ACTIVITY

Would the air flow sensor affect starting?

Thanks again

Tony

 

Can someone be lind enough to point out the location of the filter and hand prime?

This is what I am looking at



I have searched no end and cannot seem to find anywhere that tells me where the fuel filters are on this model.

One would think that the hand primer would be slightly accessable by hand!

 

The 2.5 has the filter by the tank, the 2.8 has it in front of the engine.

The MAF fault shouldn't stop it from starting. It's normal for the fuel pump to run when you turn the ignition on, though it should be fairly quiet.

Disconnect the feed line to the injection pump and check you are getting a decent supply of fuel when the pump runs and that the fuel comes out clear and not "frothy" with air bubbles.

Regards
Ricahrd

 

Just found the fuel filter housing when it was in the air at ATS getting a tyre fixed.

Will test the fuel supply later today.

Is there a one way valve anywhere in the fule lines on the 2.5?

 

OK, I give up! Where is the feed line to the injection pump?

I cannot see the thing anywhere. They really crammed that motor in there didn't they!

ALso, is it really necessary to remove half of the front of the car, inlet manifold elbow & alternator to remove the glow plugs?

 

Sorry to hear you have no workshop manual, they are almost impossible to find particularly the diesel, if you find a copy let me know.

If you open this and look for 14a FUEL SYSTEM 2.5L you will find a schema in 14a - 2 FUEL SYSTEM.

The book covers the fuel system on the 2.5L OR 2.8L Common Rail Diesel (CRD) Engine uses a high pressure pump and an Electronic Control Module (ECM). (Fig. 1)

The fuel delivery system consists of the:

•Accelerator pedal
•Air cleaner housing/element
•Fuel filter/water separator
•Fuel heater
•Fuel heater relay
•Fuel/Lift pump
•High Pressure Fuel injection pump
•Fuel injectors
•Fuel tank
•Fuel tank filler/vent tube assembly
•Fuel tank filler tube cap
•Fuel tank module containing fuel tank vent valves and a fuel gauge sending unit (fuel level sensor).
•Fuel tubes/lines/hoses
•High-pressure fuel injector lines
•Low-pressure fuel supply lines
•Low-pressure fuel return line
•Overflow valve
•Quick-connect fittings
•Water draining

For myself I don't have a 2.5, I hope the schema and tests help !

 

you can get to banjo fittings on the injection pump by removing the 3 bolts on the power steering reservoir and moving it over a bit - BUT there are a bugger to get the copper washers back on without removing the alternator as well.

Regards

Richard

 

Hi Richard,

Thanks again for the reply, much appreciated.

I am still having trouble finding the pipe

The one I can see appears to go from the pupmp to the fuel rail.



Would this be the one or am I looking in the wrong place?