TD5 Starting Issues

Hi guys looking for a TD5 guru, have done a head gasket replacement on my disco and cannot get it started.
Things i have tested so far:

Compression - 350-420 psi across all cylinders
Timing - couldnt get it any closer if i tried
Injectors - injector seats cut, new washers and O rings (Bearmach parts) injector rocker shaft reset as per workshop manual, all injectors are working fine, tested using diagnostics
Diagnostics - no fault codes, CPS reading accurate on live data, removed and tested showing 1.24 ohms which i believe is fine

Current stage im at is thinking a fuel issue, removed what i believe is the high pressure feed into regulator with ignition on and im getting a fair amount of fuel coming out, obviously without a pressure tester i cant get an accurate reading. Have followed purging procedures to no avail. It doesnt cough or splutter as if it even wants to attempt a start.

Scratching my head at this and im closing in on the petrol and match stage. Hopefully someone can point me in the right direction!!

Any chance you could have knocked the inertia cut out switch by accident?

Checked that as well mate

New injector loom fitted? Triple checked all harness connections? Battery voltage better than ok?

That's my limit lol, bet it's something daft though, hope it is lol

Get a pressure test done at the fpr. I had a problem before with my Disco 2 & bought a new fuel pump. I had good voltage & the pump was doing the bleed procedure fine. I even removed the fpr & had diesel ****ing out at a good rate. Turns out the new pump was **** & when tested was about 2.7 bar, so worth checking. Think it was meant to be around 4 bar if I remember right.

Dan.

LothianAutos said:

with ignition on and im getting a fair amount of fuel coming out,

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How much is a fairamount? the two stage pump can fail on the high pressure side and still pump on the lower pressure side at a lower volume. I found a failed pump when I did not have the fuel pressure gauge at hand by measuring the fuel output. It is listed in the RAVE manual.

Cheers

When you switch on the ignition can you hear the fuel pump whining? it sometimes takes 4 or 5 bleed cycles to clear it, If so it's air in the system, do you press the throttle pedal when turning it over? Mine coughed and spluttered slowly into life last time I did the injector seals.
Pull off the injector power lead take a look if there is any oil in the plug at the front of the engine.
Good luck

Are you based in North Berwick??...

If it’s a manual you could try tow starting it

not being silly but I have heard that you need to tell the ecu which injector is where by the numbers on the side of the injectors
. have you accidently mixed them up ?

lurch917 said:

not being silly but I have heard that you need to tell the ecu which injector is where by the numbers on the side of the injectors
. have you accidently mixed them up ?

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The injectors are tested and given a code which should then be entered into the ECU so that the fuelling can be adjusted to the characteristic of each injector.
But that is a fine tuning thing just to try and balance the engine better and make it run smoother, I don't think it is a show stopper when it comes to starting the engine.

Probably fuel pump

Hi l m still looking for advice from anyone,just bought discovery 2 tdi5 04 plate won’t start until fuel pump switches off approx 30 seconds them starts ???? Any suggestions please

Snadge said:

Hi l m still looking for advice from anyone,just bought discovery 2 tdi5 04 plate won’t start until fuel pump switches off approx 30 seconds them starts ???? Any suggestions please

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You would be better starting your own thread that way it will be seen..
Regards Rob

I’ve just replaced my fuel filter housing because of the exact same problem. It gets worse the longer you leave it. What you’re doing, basically, is having to prime the fuel system on every start.

New fuel filter housing is about £120, but be aware,if you do it yourself, the two 13mm bolts holding the housing on have two 17mm nuts on the other side of the bracket. Other than that, it’s an easy job and cured my problem.

Hi steviecops thanks for your help
Regards Snadge

Shippers said:

Are you based in North Berwick??...

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Yes i am mate
Not had a chance to get another look at it recently as been too busy but basically injectors were marked and put back in the right place. As stated even if they were mixed up you wouldnt get a non start just a slightly rough running as Shippers stated its just for fine tuning. My next step is the fuel pump as the high pressure side can be stopped by placing a finger over the pipe. 4 bar should be the pressure is that right?
Have a new fuel pump sitting here so will try that and see if that makes a difference

Shippers said:

Are you based in North Berwick??...

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Was only asking as have family in North Berwick and used to live in Dunbar...LothianAutos rang a bell as a mobile mechanic outfit I've heard of...

Shippers said:

Was only asking as have family in North Berwick and used to live in Dunbar...LothianAutos rang a bell as a mobile mechanic outfit I've heard of...

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That was me but no longer mobile got sick of working outside in the Scottish weather.
Disco turned out to be a failed pump all running around well now

Thanks for telling us what it was