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[marshfarmer]

Hi all my first post. 
I have a 120k 2.7crd GC 2003 that I have had for a year, my first Jeep.  It has been faultless for 10k of heavy towing then became difficult to start in spring.  My initial thoughts were ineffective glow plugs but these all checked out ok.  I then replaced all the plastic fuel lines, which gave perfect starting for a couple of weeks then it was back to lots of cranking and the occasional sniff of easy start.  Next thing I replaced the O rings in the pressure relief valve on the end of the rail.  Perfect starting again for a couple of weeks, then more problems.  This time I noticed a diesel leak with the problems, which turned out to be the high pressure pump.  As I intend to keep the motor for another year or two I decided to treat it to a new low pressure pump and recon high pressure pump this week.  On prising the fuel lines out of the old high pressure pump I noticed I nicked one of the O rings, but despite this it started perfectly for the first 10 starts then became as normal, I swapped the offending seal for one from my old fuel lines today, which seemed fine, and it was again perfect for the first few starts and now back to requiring easy start.  In the midst of all these problems I performed a leak off test and injector number 5 (surprise surprise) returned the largest amount of fuel, but this was only about 20% more than any other injector.  The only thing I am yet to replace is the t piece in the top of the filter, which I have now ordered along with a bag of fuel line O rings just to be confident that no others were damaged upon pump replacement, and another new filter.  Does anybody have any ideas other than replacement of injector 5.  It just seems odd to me that when I replace something I see an instant improvement for a short while, which doesn't seem to point to the injector to me??  Sometimes it refuses to start hot yet is fine when cold, cam sensor has been changed also, I haven't been able to see any air in fuel lines.  In the last two weeks it has also died a couple of times under kickdown, giving MIL, but I believe this is a separate issue of faulty diesel regulator valve?? I have ordered a new one to stick on over the weekend.  Sorry for the long rambling post. 
TIA

[Bishops Finger]

Any fault codes?

[marshfarmer]

340 Replaced Cam sensor
1130
190
109
1131
1652
1685
One of the wires to the driver door broke and caused electronics to go haywire till its was repaired and battery was taken off for a while.  Thinking this was the skim key code.

[marshfarmer]

Today I fitted a bag of new green seals to fuel lines, and a new diesel regulator vale.  Started lovely about 6 times, went out on the road, tried the kick down a few times and it didn't die.  Got about 15 miles thought I could start to trust the motor again, it's been really bad for cutting out under load last couple of days waiting for parts, gave it a little to get up a hill and it died.  Wouldn't start without ether either.  Managed to get it to die under kick down in my yard and got out to have a better look, diesel was sizzling around injector 2.  The union that screws in the top of the injector was turning with the metal pipe, looks like there is some loctite applied when made, managed to tighten it down a little with a socket.  Can the injectors split round the top and cause this to loosen under pressure?  Could this be my issue.  It started again afterwards.  Didn't remove injector as don't have a spare bolt.

Where do I go from here.

[Dutch]

Marshfarmer,

Dont feel 'unloved' due to the lack of answers.    I had one for 5 years, loved the thing to bits and spend the kids inheritance on it to keep it going until I had enough.  Being spannery challenged all had to go thru a garage.

Mostly injectors (black death), fuel system, pumps HP & LP, fuel lines, abs ECU, and every MOT I seemed to have to throw a sack of ball joints at the bloody thing.... etcetera.... etcetera 

You'll find that most on here that had one have fallen out of love with the type.

Don't get me wrong, I still think its one of the sexiest Jeeps going and the ride comfort of the LTD is second to none.

I went WK 3.0 CRD and never looked back - waaaaaaay better engineered trouble free package.  (ok ball joints are still a PITA  )

Keep at it for the love of the thing or ......... burn it!!!

Cheers.

[Bishops Finger]

Aaargh BallJoints where are you Marshfarmer?

[Dutch]

Aaargh BallJoints where are you Marshfarmer?

Bish .....    you had one too didn't ya !!

[marshfarmer]

Thanks for the replies, I bought the thing cheap to get me out of a muddle when my Nissan truck blew up, and is my first 'luxury' motor and I know what I have been missing now.  I'm more of a defender/series man really.  Motor just spends it's time dragging my spuds from farm into the bright lights of Great Yarmouth, farm is on the Broads, so I leave it running all through deliveries, or dragging a cattle box about, but this cutting out is dangerous.  I know the answer is to take it to a pro, but I usually manage to fix most things on farm, but I am no mechanic.  It's so frustrating to do something then it starts fine for a while then back again, so close yet so far... I've still got to fix it to get rid.  Quite fancy moving up to about an 08 GC.  I've only done 10k in it but nearly all towing and all it needed was set of brake pads and track rod end, so can't moan other than bad starting.  I think I better order a 't' piece for the return into filter then can only be injectors I guess?  Unless the recon pump is at fault?

[Bishops Finger]

Track down Steve at FTE in Essex

[Bishops Finger]

mmm WH Jeeps the biggest thing to go laning in short of Witham Auctions...

[Mike Pavelin]

Track down Steve at FTE in Essex

He doesn't do repairs.

[bgbazz]

I seem to recall a Birty using a travelling mechanic (he comes to you), some years back...might have been Dutch, but not sure.

Anyway, the comments at the time were encouraging...maybe he's still around and could sort it for you.

Just a thought.

[marshfarmer]

Thanks for all the replies.  Stuck another new filter in yesterday.  Could see air creeping in the lines.  Every clip is now broke on these two month old lines from having them in and out a couple of times fitting pumps etc. So I'm bound together by cable ties.  The green o rings seem to fit much better.  Took the t piece out of the filter.  I take it the arrow denotes it's a one way valve.  I could blow through it both ways.  Have ordered one.  Have started it about 6 times but not been out yet. 
I'm starting to wonder why I ordered a new lp pump.  Thinking I should have found a basic filter with just a 10mm in and out, and stuck an electric pump in to feed the hp pump. 
If the damn seats were not so comfortable I would have tracked a digger over it by now 

[daggie]

 
take the seats out ! 

[marshfarmer]

Not a bad idea, but I would miss the after a ride in the 90, if I had a swap.