2000 Discovery 2 TD5 - Wont start after head gasket replacement :(

im pretty confident on the timing as my mechanic set it, and ian (justfishing) double checked it for me.

I just put a multimeter on one of the injector plugs - very low voltage (under 0.5v) whilst cranking. What should they be and can they be tested with a normal multimeter?

Injector volts around 90volts as it fires not easy to measure with multimeter.
Your reading should be ok as you are just getting a flicker of power as the injector fires did you replace injector loom do you have oil in the red plug.

Ideally need a tester nanocom etc for checking injectors.

Noisy CKP sensor can be caused by starter contacts being dirty/worn this gives bad signal when cranking so bad injecting.
Have you tried to tow start if its manual it will rule out noisy starter.

TD5s will start if pump is failing if it has 3/4tank and above.
But won't pull well above idle due to lack of fuel.

Any joy testing fuel pressure?

When you get it to start does it idle ok?

Hello,
I put the pin in the flywheel and the pin dropped in the top slot, the valves were both closed, so should be right YES ?? I did notice that the injector cam was not at max depression. Also hooked up my evo and had faults on, crank sensor, also all injectors had faults. Did the injector test and you could hear them clicking as we did each one, could they still be all bad ??, . had a look inside the ECU (MSB type) no oil. Red plug clean there and the Black plug at head also clean, Ryan did say there was oil at the red plug when he first looked.....when cranking the engine sounds good no knocking or abnormal noise. .
Hope this helps I am not back till next week.
Ian

injectors all tested fine with the nancom - also if i put 12v to them individually i hear the 'click'. I was thinking that this does not necessarily mean that they are getting power whilst cranking though.

There was some oil on the red plug which i cleaned off.

I did try to use a test light to test the voltage whilst cranking and nothing happened. Surely either the light would of come on, or at 90V it would of blown the light- but its still fine :) So im very suspect.

The starter is not the best , it only cranks 50% of the time, the other time it just makes a horrible noise. I do recall seeing Noisy CKP sensor on the list of fault messages too. It's an auto so can't tow start.

It barely idles, sits at around 1000rpm and will not rev at all. I only have half a tank.

I need a fuel pressure test kit , ill try to source one tomorrow...

I think you have a fuel bleeding problem at the fuel filter housing check the one-way air bleed valve maybe blocked not allowing air to bleed from system
Also I dont think 10 liters will be enough fuel

Denso part numbers
2X copper contacts
Contact set 10295 8mm
1X Plunger 7371

Ideally new ones fitted but they can be cleaned up to make better
contact but its a pull starter out job.

I also think failing pump or junk in fuel system FPR gauze filter
main filter blocked pump lots to look at but test pressure first
and get starter issue sorted.

Your getting there its a pain getting a half done abandoned job
to completion but its worth it.

but would a starter which only cranks 50% of the time (but cranks hard when its going) stop the engine from starting?

Hard to tell from where I am but TD5 need lots
of volts to start and run ECUs does not
take much to upset one.

When you use the starter, it creates 2 magnetic fields.
1 from the solenoid & 1 from the starter motor itself.
The crank sensor uses a magnetic pick up off the flywheel.
What is happening is that the crank sensor wire is picking up the starter motor fields which is not 5 pulses per revolution of the engine.
The noise to the ECM probably sounds like static on the radio. remember fitting suppressors to alternator to radio to cure interference.
The ECU won’t like this & throws fault code

Dirty contact will also need higher current to flow dragging power from ECM

Iv heard of people using aluminium foil around the CKP sensors wiring to stop interference getting picked up.

I can't guarantee but its worth a try.

an update :)
I pulled off the fuel pressure regulator to check the gauze filter for blockage. Found a bit of gasket cement in there , replaced the regulator but unfortunately its made no difference. I am a little suspect of the gasket - am i using the right one?? It doesnt quite look right.

http://i1238.photobucket.com/albums/...psbba90bdd.jpg
http://i1238.photobucket.com/albums/...pse534380b.jpg

I also borrowed a test light specifically for injectors. The light does not come on at all when plugged into the wiring harness. So im still wondering if the injectors are coming on, although when tested with nancom they all click when triggered. Unless this test light does not suit diesel injectors, i dont know.

http://i1238.photobucket.com/albums/...ps5f97cb4c.jpg

Finally, i pulled out a couple of glow plugs , they look a little wet with what appears to be oil (or maybe just dirty diesel). When the engine cranks with the glow plugs out you can hear good compression.

Unfortunately i am thinking its time to call in an expert as i am really stumped!

http://www.aulro.com/afvb/discovery-...p-engines.html

The pulse of power may be to quick to pick up
with a light or meter.

Get all the easy stuff looked at first starter
fuel pressure just re read my post on fuel pressure
I put up the wrong thread for temp sender it is M12x1.5

Change fuel filter