A few days ago my Disco died on me at a stop light. It ended up being the fuel pump, but I wasn't sure. I am no more than a "shade tree mechanic" so I found this site, solicited advice, and received a lot of good feedback.

I am posting this to hopefully save someone with the same issue a little time...

2004 Disco 90K miles.


First symptom was intermitent hard starting. No particular when hot or cold. Sometimes would kick right over, sometimes had to crank for several seconds and give a little accelarater to get started.

Second symptom was she died at a stop light and would not restart.
After getting her home I went through the normal process of diagnosing my problem. My normal process consisted of popping the hood and looking at it and going "what the *%&^ is wrong?"

The 2004 Disco DOES NOT HAVE AN INLINE OR ANY OTHER FUEL FILTER THAT I COLD FIND other that the screen on the bottom of the fuel pump itself.

Being the owner of "out of warranty automobiles" I always have a can of starter fluid handy. Got the Disco to fire and hold idle. (The engine vacuum was enough to support this.)

The fuel pump was running. It is easily accessed by pulling the carpet back, 6 screws in the access panel, the locking ring came off with a few taps of the big screwdriver and a ballpeen. A VERY light pry on the edge of the fuel pump (all plastic) and she will come straight up. (She will also be full of fuel, so have a bucket or... handy)

My keen mechanical eye told me that there were no broken wires, hoses, or anything else that I could see. Connected direct to the battery and she kicked on and ran. Sounded good. Put it back in. Reinstalling did not fix the problem.

Long story short - if this happens, go get a fuel pressure guage, find the pressure check valve on the fuel rail, and test it. Mine showed 14 PSI. The folks here advised that it should be 30+. they were right.

The test port is a little hard to get to. Use your right hand , reach to the back of the engine, under the wire bundle that runs along the top of the firewall. You can't see it but you can feel it. It will have a metal cap.

Connect the guage and start the truck. Use starter fluid as necessary. If it is not in the high 30's psi - fuel pump is bad.

I did find a used fuel pump out of a wrecked 2004 disco. $100. The truck had about 45K miles, so I figure I should be good for anothe 45K since mine went at 90K miles.

Hope this helps and thanks to all of those who guided me through some diagnosis and suggested solutions.

 

Will the engine start with starter or carb cleaner, run and then die? If so I would look at the cranks sensor before throw a pump at it. If the crank sensor has failed you will not get any fuel cause the ECU doesn't have a signal indicating the engine is turning over.

 

Nice update, thanks.

I know from others, (I'm about to try) that some other fuel pumps work in the DI's,

GM's air-tex, for one. ($50-70)

I'm not certain about DII's, but suspect the same.

luck,greg

 

Great job!!!!!

 

Greg,

I just finished a teardown and then replacement of my fuel pump on my 1997 Discovery I. Mine had a crack in the plastic top by the line out. I attempted to replace the metal tubing going thru the top plastic plate but could not get a suitable seal there.

I ended up buing a new Pro Line Fuel Pump from Rovers North for $105. It has straight non flared ends on the feed and return lines, but the compression fitting and bushings were available for just a few dollars more. With a new rubber bushing and shipping it was roughly 150 bucks.

It is an exact drop-in duplicate, mine works fine. I highly recommend it to all DI owners.

 

DL--

I already bought mine, ($50), but that's good to know,thanks


luck,greg

 

Anyone want to rebuild my old fuel pump. read somewhere in another thread that it "only needs new brushes." It is the one pictured at the top of the thread.

 

: o) I really love this - That my friend made my day!

Cheers

Robert