P38A 2.5 Diesel wont start

Hi all
I have 1998 RR 2.5 Diesel P38 automatic, witch does not want to start.

I will start from beginning:
I was going on a trip when I noticed fuel tank was almost empty (orange led was lit and it was 1/2 of the first section on gauge). I drove in gas station fueled it up about 30l. Cranked the car, it took about 10 secs, but it started (I thought maybe as tank was empty and my pump may be a bit worn -it`s ok. PS> I never before drove on such low fuel in tank. Last was minimum 10l to 15l in tank when I filled up again). So I drove off to shop (about 20km) and parked there. Went to shop (about 2-3 hours) and when I came back there was "ENGINE DISABLED PRESS REMOTE" on dash (I have disabled passive immobilization ect. because I open door with key as my fob got unsynchronized a wile ago). So car wouldn't even crank. I tried to enter EKA, but as it was disabled, car wouldn't even accept it. In process of trying to start it I might heated glow plugs 10-20 times. I decided to disconnect and reconnect battery. Did that and message was still on dash. But when I closed drivers door, message disappeared and I could crank it. But unfortunately after 5-10 times of trying battery was too weak and car did not start. Got some help and connected battery's with other car but still no luck. Got fuel and pour 20 more liters in tank. Connected battery's with other car again - car cranks but wont start. Got easy start gas - injected in air inlet, cranked a few times. At first it was like trying to start, but never did. I think fuel maybe is not delivered to engine.!? Towed car home an now trying to figure it out.

In summary:
Got "ENGINE DISABLED PRESS REMOTE" message on dash. Disconnected and reconnected battery, message disappeared, car cranks, but wont start.

Have no diagnostic tool on hand to check ECU, although no messages on dash.

Possible causes:

• Glow plugs dead - (changed last year. Bosch plugs)
• Fuel pump in tank dead - (transparent fuel line after filter is full with one small air bubble in)
• Fuel injection pump worn out - have no idea how to check it
• Fuel injection pump solenoid wont open - have no idea how to check it
  
• Crankshaft sensor dead - have no idea how to check it
• BeCM and ECU out of sync- have no idea how to check it

Maybe anyone have other causes in mind why car wont start?
Any suggestion and idea would help! And correct me on causes if I`m wrong.

Think you might need some diag on it.

Where are you?

Grrrrrr said:

Think you might need some diag on it.

Where are you?

Click to expand...

Latvia

Update:
Unplugged leak off pipe - fuel flows when engine is being cranked.
Unscrewed fuel line for injectors - fuel don`t flow to injectors when engine is cranked!

Put + wire to fuel pump solenoid. It clicks, but when key is turned to pos II it sounds like something else clicks in relay box and solenoid closes.
When I put + wire to solenoid when key already is in pos II - solenoid does not click.

Unplugged fuel line after filter. When key is in pos II no fuel is flowing out. (maybe pump dead too?)

So my thoughts is - maybe some error in immobilizer? It goes hand to hand with "ENGINE DISABLED" message witch I got earlier.
Its just strange that no error messages is showing now.

Can any confirm or disprove that this might be immobilizer?

You need to get diag (Nanocom) on it to check if ECM and BECM are out of sync. If they are the only way they can be synced other than by dealer diag is with Nanocom or Syncmate. If they are out of sync you can play with it for the next ten years and it will not start. I hope you did not disconnect and reconnect the battery with the ignition turned on or the BECM maybe in an alarmed state, which is a big problem.

Only option is to get car to nearest shop with diagnostic tools (it`s 50km from me). I`m not sure what diagnostic tool they have (big blue tablet) and I hope that they can do the job.
I hope so too, but I doubt that I would leave key turned when removing battery.

So if I understood correctly it sounds like it is most likely that ECM and BECM are out of sync?

Thanks for response

evo70 said:

Only option is to get car to nearest shop with diagnostic tools (it`s 50km from me). I`m not sure what diagnostic tool they have (big blue tablet) and I hope that they can do the job.
I hope so too, but I doubt that I would leave key turned when removing battery.

So if I understood correctly it sounds like it is most likely that ECM and BECM are out of sync?

Thanks for response

Click to expand...

Good diag will tell you what is wrong. Getting a Nanocom would help. They are an invaluable tool for any P38 owner specially if you are miles from help. .

You could buy a sync-mate. This tool was designed especially for this problem.

How can fuel flow to the leak off pipes but not the injectors?

There's an emergency stop solenoid somewhere. Think it might be behind the driver's kick-panel on the RHD cars.

Grrrrrr said:

How can fuel flow to the leak off pipes but not the injectors?

Click to expand...

Pressurised fuel is constantly returned to the tank, if a spill pipe is removed some fuel will run out of it. Fuel quantity to injectors is controlled by the quantity servo this also shuts the engine down. The fuel cut off solenoid on the pump is only a back up to this. If the ECM and BECM are out of sync the ECU is switched off meaning the quantity servo is inactive and no fuel can go to injectors. Fuel pump inertia cut off switch is behind R/H trim panel at base of R/H A post. Maybe a good idea for him to check if lift pump is actually working. Lift pump only works when glow lamps are on or when engine is running on this year of car. Remove relay 12 and with ignition off power the terminal that is opposite in orientation to the other three, the one nearest to front of car, with positive from battery, fuel lift pump should run. Any air bubbles in clear pipe should move to indicate activation.

I didn't think any fuel got past the FIP if the stop solenoid or the quantity servo was shut off? That's what puzzled me about his post. Obviously they'd be some residual fuel in the spill pipes but he said it was pumping?

evo70 said:

Update:
Unplugged leak off pipe - fuel flows when engine is being cranked.

Click to expand...

Grrrrrr said:

I didn't think any fuel got past the FIP if the stop solenoid or the quantity servo was shut off? That's what puzzled me about his post. Obviously they'd be some residual fuel in the spill pipes but he said it was pumping?

Click to expand...

The stop solenoid only stops fuel from being supplied to the front of the piston from inside the pump casing, it does not stop fuel from entering the pump nor does it stop fuel from being recirculated back to the tank.