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[Outback]

Hi there,

I'm new to Jeeps, got my 60th a few months ago - 2.5TD 2001 and everything's been fine so far.

I've been having some trouble getting it started over the last couple of days: engine turns over nicely but just won't fire up. I got it going yesterday morning and evening by doing slightly different things: switching off the heater (?!) and locking/unlocking. Also tried disconnecting the negative terminal on the battery, just to reset the ECU. That didn't seem to do much, at least, not until I'd tried the heater or locking/unlocking.

I don't know a great deal about it, but it seems to me like it's probably an engine management or electronic issue. I found this topic here, about the chap in Poland with starting problems earlier in the year: http://www.birtydastards.com/frm/index.php?topic=11595.0

But I have some real noob questions from this topic that I hope you might be able to help with:
I've checked my PDC and I don't appear to have a horn relay, so I can't swap one out for the starter relay. The others seem pretty important (ABS etc,) so I don't want to try it. Is there another relay that I can swap out for the starter relay, even just to test it? Also, there are 2 starter relays, 1 is large and the other small - I guess both of these would need testing?

On the topic before, it was suggested to "Bridge out" the contact - how do I do that? Remove the relay and place a single piece of wire into each contact?

Any help or other suggestions is much appreciated!

Thanks

[tim_aka_tim]

I'd be thinking glow plugs or fuel/injection pump before ECU. Are you getting any smoke from the exhaust when you
turn it over? Does it ever start, or does it just keep turning over? Is the battery in good condition?
Is the fuel filter clear?

[Outback]

I don't recall seeing any smoke before start up, but once it kicks in then it spits out a load of white smoke. Clears after a few seconds.

The battery seems ok - voltmeter on dash shows around 1/3 - I tried jumpstarting yesterday off a Golf and made no difference to it.

It does start up eventually (so far), but usually after I've tried disconnecting/reconnecting battery, and messing with the heating or lights, or locking/unlocking. Basically, trying anything.

Fuel filter - how do I check it? Is that one of the 2 cylinders on the right, at the windscreen end of the engine bay?

[Panic mechanic!]

I would think its the glow plugs starting to show their age.

[tim_aka_tim]

Yep, it's the glow plugs. Your local motor factors will have them.

[Outback]

Ok, thanks both, I'll give that a go.

Is that something that I might be able to change myself or should I be leaving it to a mechanic?

[Outback]

And how many do I need?

I'm next door to a Camberley Auto Factors now so I can if they've got some.

[tim_aka_tim]

You'll need four. It's a pretty easy job, just use a socket set with a spark plug remover.
You can test the glow plugs before hand to see if they're ok. Put the meter across them on the
ohms setting. A good one should read about 1 ohm if I remember right.

[tim_aka_tim]

Can I ask a possibly insulting question too. Given that you're new to Jeeps, and possibly to
diesels - you are waiting for the preheat light to go out before starting aren't you?

Sorry if that's an insult to your intelligence.

[Outback]

Ok, great.

I'm new to doing mechanical stuff as well, but I'll give it a go.

Just need to find where they are now....

Any pointers?   

[Outback]

No problem, I prefer if you treat me like an idiot - you'll probably be right most of the time!

If by Preheat Light you mean the Glow Plug light (looks like a coil) on the dash, then yes. I always wait for that to extinguish before starting up.

[tim_aka_tim]

Here's a picture that should look vaguely like your engine (it won't be exactly the same, but
the major bits are). I've circled the glow plugs for you (the second one is there, but hidden
on the pic).

[attachment=1]

Actually, that's for a 96. I reserve the right to be wrong on the location as your engine is newer.
Look for them near the fuel injectors - they'll have a common wire.

[Outback]

Ah, I see, that pic's great, thanks!

They should just unscrew with a socket set and spark plug remover?

[Outback]

Here's a pic of my engine, with what I believe are 3 of the glow plugs visible. (the 4th is just further back).

Does that look like them?

[Panic mechanic!]

no thats not them, they are all joined by a piece of metal that looks like a bracket and are below those bolts you have pointed out.

[Outback]

Ok, I can't quite see them on that pic. I'll have to look later and continue this conversation then or tomorrow!

I've just picked up some plugs though, so (if I can find them!) I should be able to take a look.

Any other advice? Do I need to disconnect the battery etc. any thing like that I should know?

[tim_aka_tim]

I began to suspect myself when I looked at that 96 engine and remember changing
the glowplugs on my old 3.1TD (the same engine with an extra cylinder). The glow
plugs are accessed from the top on the newer engine. I've marked them on your picture.

[attachment=1]

[Mike Pavelin]

I would check the spill pipe blank in no'4 injector first.

[Outback]

Thanks Mike - one question though: How do I check the spill pipe in no.4 injector? 

Also, it started up last night and this morning first time. Not perfectly healthy, I can still hear a little complaining in it, but it fires up straight away and it seems to have got fairly cold overnight. I'm booking in for a service so I'll hang on before looking at the glow plugs. I'll carry them with me though, so if I can't start it sometime then I can replace them and see if it works.

Looking in the engine bay a minute ago, with the engine running, I noticed a couple of things that I'd like to run by you guys. On this first pic, the canister right in the middle of the picture with a yellow cap on (some kind of a filter?), I noticed after I stopped the engine that there was some dripping, clear liquid from the base of the canister. Smelled like diesel - is it the fuel filter? Could be an O ring or something?
[attachment=1]

Also got a pic of the engine here. Quite a lot of black around the engine, is that a sign of an oil leak? Or is it expected?
[attachment=2]

Last pic, really not sure what's going on here. This is almost directly below the canister I asked about earlier. I've pointed out a pipe that just seems to be cut-off, not connected to anything. Anybody know what that's about?
[attachment=3]

[daggie]

last pic looks like an aircon pipe
1st pic, yep thats the filter, put a new one on, any leaks the will cause starting probs
the spill pipes are the little braided rubber pipe linking the injectors together, the pipe on the last injector usually splits

[Mike Pavelin]

Looks like the high pressure line from the A/C compressor is broken. If there is diesel leaking from the fuel filter, it can also draw in air overnight and cause your starting problems.