2.5 N/A Diesel running on 3 cylinders

running on 3 cylinders

Hi folks can anyone help out. I own a lightweight with a 2.5 NA diesel (early defender engine) which will only fire up on 3 cylinders.
Here's some recent history.

The head gasket blew some time back so had head checked and found to be cracked. Bit the bullet and did some major work. Sourced a replacement head which was skimmed and pressure tested and was a good one.
Fitted new pistons and rings along with new conrod shell bearings.
The bores were deglazed and no cracks found.
I've had all 4 injectors serviced and replaced the heater plugs and all the associated wiring too.

When i first tried to start it i kept getting air bubbles from the injector pump and it eventually killed the battery, so bought a new battery and replaced all the fuel lines, removed the tank selector tap(so direct fuel line from tank) and ended up getting a tow start from a friends landy and thankfully it fired up.

Now it fires up first time every time but only on 3 cylinders????
It will not fire up cylinder no1. I know its no1 as the exhaust manifold stays cold on 1 but hot on 2,3 and 4. Have swapped injectors and heater plugs around but still no joy. I get lots of white smoke showing unburnt fuel and is running like a bag of spanners and will never pass an MOT.

The injector has a fantastic spray pattern so know its not the injector pump.

Have checked the valve gaps and the tappits are doing their thing too.

I'm stumped.
Anyone have any ideas so I can bring this beauty back to life.
Cheers

Just saw your post. I had the same problem a few months back with my 2.5 na. I spent weeks going through all the other possablities such as the gasket gone again but only around pot 1, the valve settings, the pistons and even the head again but it turned out just to be as simple as the washeres for the injectors. The ones that sit right in the head and seal the injectors once their bolted in, i was missing the lower one and as i'm sure your awear deisel engines run on compression and as a result of the missing washer pot 1 was loosing just enough compresion to prevent it from firing.

I hope this can through any light on your situation

Thanks for that. I'm not sure if i replaced the inner washer but did change the larger copper ones. I'm gonna nip out first thing monday and buy a new set, stick them in and give it a try.
Its not something i would even have considered. Cheers for the heads up and I'll let you know how i got on
Thanks

Hi there

Got new washers fitted but went to try and start it and found that air had got in the fuel lines cos I'd left the injector off and it won't fire up. Ringing my mate to come round and tow start me to bleed the lines again. Then we'll see if its cured it

Nothing is ever easy in my house!!!!
Thanks again.
watch this space.

You should not need a tow start to bleed the lines.

When I changed one of my injectors I just:
1. used the small leaver on the bottom of the fuel pump to re-pressurise the fuel system
2. put a rag round the bleed line banjo bolt
3. loosened the bolt to let the bubbles of air out
4. tighten the bolt
5. repeat on all injectors until all the air is out.

Hope this helps

Its fixed.

You are an absolute genius. Who'd have thought that a 10p washer would cause such a problem.

I went to bleed the lines and noticed that i had a dribble of fuel at the splitter banjo on the output from the lift pump so quickly swapped the line with spare pipe i had and tried bleeding but it was taking ages so my mate dragged me up the street for 30 seconds and we're up and running. No air, no leaks and firing on all 4 pots. AWESOME.

It runs a dream and ticks over with no smoke at all. Brill. Booked it in for MOT on wednesday, Even gave it a good wash. Ironic really that I've now got a faulty rear indicator. Good job i've got a spare lens unit in the shed!!!!!! Typical.

Anyway just want to say thanks for the advice. You're a star.