I have a 2001 Rover 75 with the BMW 2.0 CDT diesel engine, now showing 111,000 miles. It was running fine when I last used it, but a week later it would not start – it was cranking over well on the starter, but would not fire. I checked what I could – such as the fuses – and operated the door locks with the ignition key several times, but the engine would not fire. A mobile diagnostics team checked it, but didn’t find anything wrong.
I checked for fuel in the line – ie, under the bonnet, fuel pump and filter, etc – all of which seemed OK, but no fuel was being delivered to the common rail. I changed the camshaft sensor, but this made no difference. I have since talked to a couple of Rover mechanics and they said it could be the Bosch injection pump, although this a pretty reliable unit. I believe there is a valve on the injection pump body that may benefit from cleaning, but I have not touched this yet.
Up until this problem, the vehicle was running fine and not showing any faults on the dash. It has always started first time, hot or cold, and has never been run low on fuel. It is well maintained and always garaged when not in use. Russ Bedford
You will appreciate that if a mechanic who has had the benefit of actually testing the vehicle has not been able to remedy the problem, then it can be a difficult task from a distance. As you have had a mobile diagnostic firm out, I am assuming the codes were read, but none was present. I'm also assuming that the fuel lines up to the high-pressure pump were full and that the electric low pressure pump was working.
From the information you have supplied, there are two possible causes. The first is that an injector is allowing the fuel to bypass it, preventing sufficient pressure from building up in the common rail. However, if this were the case you would have an engine management light caused by a low pressure in the fuel rail. Nevertheless, I would carry out a leak-off test on the injectors to ensure this is not the case.
The leak-off test is done by placing the leak-off pipe from each injector into a receptacle. The leak-off return should be blocked off, then, by cranking the engine for a couple of minutes, the fuel coming from the leak-off pipes can be measured. The level in all receptacles should be equal, so if one is much higher than the others, this indicates a faulty injector.
As you have had no previous problems and the fault appeared without any prior warning, I would be surprised if the problem was an injector. The most likely cause is the high-pressure fuel pump. As you point out, there is a fuel pressure sensor and inlet filter on the Bosch pump, which may benefit from cleaning.
A non-starting 2001 Rover 75 may have problems with the injectors or fuel pump.