Help! Td5 wan't start after hgasket change

[German Grüner]

I was helping a mate to change his 2001 Disco's headgasket as it was suffering from the usual "pressure to coolant" trouble.

His Disco was running ok, we toke some pictures from all ancillaries, hoses, etc., and after that we dismantled it, revised and put right the head, new genuine gasket, position pins, worked with all RAVE documents in order not to forget any detail, special sealant or torque/angle adjust. We ended the work very confident as there was no difficult.

The problem is now, we tried to start, the workshop manual says, we shall turn ignition on for 30 seconds, to bleed diesel system.
We make it, the pump starts, and stops approx. 10 seconds later. Then we try to start, with accelerator at top position, as described, but there is nothing. We repeated this procedure a couple of times and the engine turns, but didn´t come allive.
Connections are good, no leaks, timing is good (the marks are good), all sensors clean, exhaust is blowing...
Fuel is coming through the pipes...

What are we forgetting?
No testbook, what can we check to know if the Ecu is avoiding our final success?
Thanks in advance!

Regards

[Hendrik]

From my experience, it seams that there is air in the fuel system, so the pump keeps sucking air and doesn't have a chance to suck up any fuel. What you have to do is pump the accelerator pedal 20 times in 60 seconds (I think, someone please confirm) with the ignition turned on. The check engine light should illuminate and the fuel pump will attemp to bleed tha air out of system. This is just a guide, I did this once but completely forgot the specifics, perhaps someone could confirm.

Another way to bleed the system, is with the pump running, undo the suction hose at the filter untill diesel starts leaking out then then reattach it and the pump should have a chance to suck up some diesel. I did this when I 'double o-ringed' a filter change.

Hope that helps

[Blknight.aus]

I find I get a good start after an injector change if I let it prime 3 times.

you did put the injector harness plug back on right?

[justinc]

Prime system with key turns about 4 or 5 times, make sure the battery is turning it over fast, and hold accelerator pedal to the floor while cranking.

Main thing is make sure battery is fully charged and engine is turning over quickly.

JC

[Graeme]

.. and hold accelerator pedal to the floor while cranking.

What does this do JC? I remember reading somewhere in the WSM that the throttle position is ignored until the engine reaches a particular rev that indicates its firing.

[German Grüner]

Thank You all for the suggestions.
Dave,
the injector harness is good reinstalled.

Regards

[Blknight.aus]

did you check that the injector harness plug ( the one under the head) was installed correctly.

about 30% of the rebuilt td5's that Ive helped out on after rebuild that seems the be the killer. for some reason the thing occasionally decides not to click home then when you kick it on the starter it drops down.

[German Grüner]

Still not firing, and we checked this harness twice.
Today we measured ckp sensor output at the ECU connector. It was 0,46vac measured with digital multimeter. Workshop manual suggests 2 to 3 vac.
Is this ok? Did anyone measured this?
Now we are bleeding the fuel pipes...

Regards

[German Grüner]

There was a lot of air into the tubes. Now all fuel pipes are clean with diesel.
...but the engine still don't start.
My doubt is now the ckp sensor. The only thing we did is to clean its connector without dismounting it, but i find our measurement too low comparing with specs...

thanks in advance
regards

[German Grüner]

Just after checking all fuses, that were all ok, my mate bleeded with the fuel pump once more. He tried to start and it started as usually!
The headgasket work toke 3 days, including head check & valvle job. To start the engine again toke us one week:p

Regards