Rough idle D2a TD5

[Brooksy106]

New head - leaks oil past the guides and seals
New genuine washers and orings (twice) doesn't leak into the rockers (dye test three times)
Injectors sent away for testing to make sure they aren't leaking (Heavy diesels destroyed one injector and refused to test the rest).
Bought 5 remanufactured injectors from Merlin in the UK - they come with orings and washers pre fitted.
5 injectors fitted and coded to the ecu by me using my nanocom
Car idled beautifully and revved smoothly when up to temp - then shut down overnight
Started on the button a couple of times
Started and moved out of the workshop this morning - idled smoothly.
Had it sitting in the drive while I washed it - started on the button and was smooth
Went to take it for a shakedown run and got 10 or 20 metres and it had no power and is idling like its running on 3 cylinders.
No oil in the red plug, never allowed to get bad so no oil in the ecu (opened it up and checked this afternoon)
No faults registered

I am at my whits end. It has been perfect. Changed the head due to diesel in the fuel and two potential overheating episode (had the old head tested hardness good and no leaks from fuel system

[sierrafery]

Turn ignition on 2 and fully push the throttle 5 times, the EML should start flashing then listen in the engine bay, can you hear intermittent hissing sound from the FPR area? ...wait untill EML stops then start the engine and see if it's the same or not, according to the results we'll speak again

[Brooksy106]

Turn ignition on 2 and fully push the throttle 5 times, the EML should start flashing then listen in the engine bay, can you hear intermittent hissing sound from the FPR area? ...wait untill EML stops then start the engine and see if it's the same or not, according to the results we'll speak again
Thanks. I have purged the system three times. Once before starting after putting in the new injectors and then twice more after it starting running rough. Made no difference at all.

[Markf]

Long shot but have you replaced the air bleed valve at the fuel filter ? AFAIK the only way to determine if it’s good or bad is to take it out and cut it open. Of course then you’ll need a new one anyway.

[Brooksy106]

Long shot but have you replaced the air bleed valve at the fuel filter ? AFAIK the only way to determine if it’s good or bad is to take it out and cut it open. Of course then you’ll need a new one anyway.
The filter etc was replaced 2000km ago Mark. It ran at idle as smooth as silk for 30 minutes total.

[Markf]

The filter etc was replaced 2000km ago Mark. It ran at idle as smooth as silk for 30 minutes total.
Did you replace the air bleed valve though ? Td5 Fuel check valve | LandyZone - Land Rover Forum (https://www.landyzone.co.uk/land-rover/td5-fuel-check-valve.241533/)

[sierrafery]

Can you hear a loud(ish) intermittent hissing sound in the FPR area while it's purging? if not the pump works only on LP which you can check this way Disco 2 - Check Td5 fuel pump HP | LandyZone - Land Rover Forum (https://www.landyzone.co.uk/land-rover/check-td5-fuel-pump-hp.358086/)

[Brooksy106]

Did you replace the air bleed valve though ? Td5 Fuel check valve | LandyZone - Land Rover Forum (https://www.landyzone.co.uk/land-rover/td5-fuel-check-valve.241533/)
isn't the bleed valve the white doohicky on the bottom of the new Mahle filter?

[V8Ian]

isn't the bleed valve the white doohicky on the bottom of the new Mahle filter?
I think you'll find that's a water drain. [bigwhistle]

[scarry]

I think you'll find that's a water drain. [bigwhistle]

Well,not all the time,sometimes they break off and drain lots of deisel....don't ask me how i know[biggrin]

[Brooksy106]

Can you hear a loud(ish) intermittent hissing sound in the FPR area while it's purging? if not the pump works only on LP which you can check this way Disco 2 - Check Td5 fuel pump HP | LandyZone - Land Rover Forum (https://www.landyzone.co.uk/land-rover/check-td5-fuel-pump-hp.358086/)
Purge is good. Makes all the right sounds. When I switch the ignition on now, that pump starts to make the same sound as if it was purging. It calms down but takes longer than normal. I have no diesel leaks, I didn't disconnect the lines when I did the injectors - I just waited a couple of days before I took them out (as getting the hoses off and on is a PITA. Last time I did them though I replaced all of the orings.

[Brooksy106]

Can you hear a loud(ish) intermittent hissing sound in the FPR area while it's purging? if not the pump works only on LP which you can check this way Disco 2 - Check Td5 fuel pump HP | LandyZone - Land Rover Forum (https://www.landyzone.co.uk/land-rover/check-td5-fuel-pump-hp.358086/)
yep sounds fine. It does make a similar sound when turning on the ignition and for longer than I remember it. Had to pump it to get it started this time. Will get the multi meter out and report back thanks.

[discorevy]

If that checks out, then revisit the cam timing, if the cam sprocket bolts were even a bit loose ( should be 37nm) then the sprocket will move causing these symptoms as well.

[Brooksy106]

If that checks out, then revisit the cam timing, if the cam sprocket bolts were even a bit loose ( should be 37nm) then the sprocket will move causing these symptoms as well.
Thanks will have a look but its not that long ago I had it off and put new bolts and torqued them up. Will check in the morning. Went into my tool drawer dragged out the fuel line pliers got under the car to take the hoses off so I could get to the valve at and found a typical LR WTF of....they have the hoses too close together to be able to access the buttons on the clip.