It has been many many moons since I last had any issues with my TD6

BUT

like most things they eventually break !

So heres what happened

I noticed a slight increase in cranking to start engine from either warm or cold - this was only an extra second or two

Driving normal 30mph round town no difference at all

Try to make a quick get away and I could feel a tiny flutter in the revs

So decided to go onto local by-pass and gunned it in Sport Manual mode Well 1st 2nd 3rd and then PING PING PING PING - Engine stopped and total non-start - whoops

Fuel System Fault on display and had to get a mate to recover me

Under side of engine dripping wet with pure clean diesel

Back to my workshop and quickly identified leak from High Pressure pump

So off I went to consult the Range Rover workshop .pdf, Google, Ebay and Youtube

Off to a local Motor Factors who advertise on Ebay who supplied me with a pump removal / cam chain gear holding tool - £20 Bargain

Then let the strip down begin

Detach bonnet struts and lock bonnet in upright position using the tabs on the bonnet hinges

Viscous fan and cowing off

Drain coolant

Rear bulkhead panel off

Inlet manifold off

Partially remove and move away the plastic coolant hose that goes directly over the HP pump

The pump is then clear to remove (no really it is that easy once tha above removed)

Remove blanking plug on front timing chest that covers the HP pump nut

Fit £20 tool which consists of a collar (fit this first) remove nut which is not very tight and then fit support tube through centre of collar

Remove the 3 HP pump nuts but remember to put a piece of masking tape across socket opening to "grab" the lowest nut so it doesnt drop into engine bay

Remove the HP pump to rail metal pipe and the feed and return hoses

HP Pump is NOT "timed" so it does not matter what position the engine is in when removing the pump

Screw bolt into the removal tool and carefully tighten which then releases the pump from the gear which is tapered

A bit of wiggling around and pump is out !!!

Clean exterior of pump

Then watch YOUTUBE VIDEO's as they are very informative !



Buy a seal kit I paid £16.20 (cheapest parts bill for an L322 Range Rover)

Failed seal that caused all the grief is pictured next to the 50p

Now I know you are all not going to have access to test equipment but even though I trust my own repair work I still went to a diesel specialist and paid then £20 to pressure test and cycle the pump throughout its working pressure range - 1350 Bar

Refit and restart engine (doesnt even need bleeding) - check for leaks - NONE

Hope this quick write-up helps others

Only special tool required is the cam gear holder / pump removal tool

You dont even need to jack up the vehicle or use a pit or ramp

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Great stuff, stan will wiki

Link to the custom tool would be helpful  .
Experience is the only genuine knowledge, but as time passes, I have forgotten more than I can remember
Volvo V70 P2 2006 2.4 Petrol 170bhp Estate SE
MG Midget Mk1 1962

Previous: L322 Range Rover TDV8 3.6 2008; L322 Range Rover TD6 3.0 2002; P38A Range Rover V8 1999

Joe90 wrote:

Great stuff, stan will wiki

Link to the custom tool would be helpful

Yep that's the one

Great write up, thanks for the info.
hope I never have to do mine
greg.

Thanks for taking the time to do the write-up  2007 TDV8 VSE
2003 TD6 gone.
2002 P38a gone
1999 P38a gone
1997 p38a gone
1993 VSE gone
1992 VSE gone
1966 Series 2a with V8 conversion gone

gregdav wrote:

Great write up, thanks for the info.
hope I never have to do mine
greg.

wayneg wrote:

Thanks for taking the time to do the write-up Thumbs Up

No probs at all

I have done a couple of similar write-ups for GM Auto Box and EAS

L322's are just big Meccano kits really

So.... it seems that this has happened to my pump.... - drip from pump when running, no drip when not.

How long would you say it normally takes to carry out this repair ?

Cheers

sjoconnor wrote:

So.... it seems that this has happened to my pump.... - drip from pump when running, no drip when not.

How long would you say it normally takes to carry out this repair ?

Cheers

Suggestion May be this thread should be re -titled INJECTOR PUMP REPAIR as fuel pumps are in the tank.