Slow starting 1.9 TDI mk2

[Marwardo]

Hi all

We have lately had some starting issues With our Ford galaxy. First it turned out to be a faulty glow plug and after changing those and changing fuel and air filter it has been running great again. But it is still intermittently very slow starting turning for a long time before starting but every now and then it just fires up right away.
Iââ,¬â,,¢m suspecting the in tank fuel pump, since it is running perfectly after it is started and when I hear the ââ,¬Å"squelchââ,¬Â from the fuel pump is always starting right away.
So Iââ,¬â,,¢m guessing either a faulty relay, pump, loose connection or a pressure switch?
I have checked relay 109, but that is of the newer grey type and seems to be working just fine. Is that the primary relay for the fuel pump?
Fuse(14) is fine.
Does anyone have diagrams for the 1.9 TDI?

Looking forward to any good inputs

Kind regards

Martin

[brianh]

Slow starting as in the engine sounds like its turning over too slowly? If so it may be a sign of a problem with the starter motor (maybe not the motor itself, could be the connections to it both on the motor after the solenoid and before or the cables involved). Given it does start unlikely its the battery though.

Relay 109 will usually cause the door led to blink rapidly - and is normally intermittent when it starts failing. It supplies power to the immobiliser rather than the fuel pump and if the joints have gone dry it doesn't work as the joint moves about - giving the fusebox area a smack or slamming the door can be enough to jolt it back into life but you need to either resolder the relay or replace it (resoldering isn't major, if you can manage to get the relay out of the fusebox you should be able to manage that bit once you've got the top off the relay).

What year is your mk2?

[Marwardo]

Sorry not that kind of slow starting it turns just fine, but it doesnââ,¬â,,¢t start until it has turned a while most likely from lack of fuel.
The new grey type relay has no need for resoldering (no pcb) and I had it taken appart and works perfect. Is there another relay for the fuel pump in the fuel tank?
Itââ,¬â,,¢s a late 2002

[brianh]

Not aware of another relay, but problems with the pump in the tank aren't unknown with the diesels, You can gain access from above by lifting the carpet, theres a panel in the floor you can see once the carpet is lifted up, If you start lifting it back from the rear righthand door you don't need the whole lot up (remove the seats first obviously, and I think you need to remove some of the plastic holders that latch the seats down as well).

If you want an easier way to confirm whats happening, a bit of clear fuel hose to replace a section at the front will show you whats coming up. Not sure if you'd hear the pump running if it had no fuel in it at the time from inside the car. its probabbly worth doing that first as you don't want to go into the tank unless you really have to.

Its also possible you have something in the tank that shouldn't be, its worth a good look around the pump area when you have it open if you go down that route.

[johnnyroper]

So when you initially switch ignition on do you hear the pump prime even if it doesnââ,¬â,,¢t start?

In my experience of these engines slow starting like that is typically as a result of fuel drain back overnight. Try clamping the fuel pipes going to filter and leave overnight then see if it starts. Only do this as a test and if it starts switch off and remove the clamps.
Failing that as said above some clear fuel hose between filter and tandem and also head and fuel temp sensor. That way you can see if fuel has run back and you are left with air. Once you have done this it narrows down the possible causes either way.

[Marwardo]

Thanks for all the inputs! A little Update
Went in and had a look at the Relay 109 which seemed just fine and was of the newer type. Though afterwards there has bin a clear squish noise from the fuel pump almost every time. But occasionally it has been cranking a few times before starting, so the cause might not be completely gone but itââ,¬â,,¢s good enough for now.
When I have more time I will give it a thorough check up.

Again thanks for all the help!

[Jakehands]

My fuel pump would squelch and door led blink when my starter motor went (replaced today) my issue before was it just died on me while in the process of replacing other parts