Another TD5 Wont Start!!

From the thread started by ULTRA150, I guess we are pretty much in the same boat.
4 weeks ago I renewed the injector harness-no oil getting to the ecu but did it anyway before it got there & I renewed the oil pump bolt that can often fail.The car ran perfectly for a week & covered about 400 miles over christmas.No issues up til now & no excessive fuel consumption.
But for the sake of it, heres my list of attempts to fix the problem to no avail...

Symptom-started from cold 3 weeks ago, got 100 yards up the road, engine cut out as if run out of fuel.

Attempts-
-Turned engine over, cranked but would fire only for a second & conk out.
-Bled system by turning key & waiting several times according to manual & several landy forums & workshop procedure, still wouldnt fire.air could be heard being purged from the system & then the hum of the pump running which then stopped after a couple of minutes.I tried this for three days & charged battery twice while doing so.
-Tried easy start in the inlet manifold, ran on that but still wouldnt run after it had burnt that off.
-Tried a bump start-still nothing
-removed fuel filter, turned key to run pump, diesel was being pumped from filter head so assumed pump working.
-tested glow plugs-all 4 knackered so have renewed-still wont start
-removed inlet & outlet pipes to fuel pressure reg,diesel present in both so assuming diesel is getting to injectors & coming out the return pipe back to the fuel tank.
-fuel pressure reg not leaking & removed it to check gauze filter inside, all good-replaced gasket
-also checked fuel cooler-all good
-replaced injector washers
-replaced air flow meter
-cleaned & tested crank sensor
-ECU clear of oil
-new fuel pump
-new air bleed valve on filter head
-no leaks in fuel lines
-diagnostic equip not giving any fault codes

The old fuel pump could be heard humming for about 4 minutes which is far longer than normal & couldnt be heard purging air-the new pump does the same.
Does anyone think its worth sending the ECU off for testing?
Or am I now left with probably a cracked head?
I am tomorrow flushing the inj loom from rocker box to ECU with meths.
Any further ideas greatly received
thanks
Foss

Have you checked the inertia switch and the multi plug on the back?

Was it a full diagnostic or fault code reader that your vehicle was put on? If full diagnostic what were the fuel pressures like? Have you changed the fuel filter? How much fuel is there in the tank? Is there signs of diesel in the engine oil?

UPDATE
Am now almost certain after speaking to an LR Master Tech that its oil in the engine-ecu harness left after my leaky injector harness.
Changing next week as the guy said he has changed "many" of these units....
Wheres my warranty recall!!???
Patent part available from here @ £155 as opposed from LR's £250
Famous Four - New Parts for Discovery Series II 1999-2004 Models - Engine - TD5 2.5 litre 5-cylinder Diesel

ratty said:

Have you checked the inertia switch and the multi plug on the back?

Was it a full diagnostic or fault code reader that your vehicle was put on? If full diagnostic what were the fuel pressures like? Have you changed the fuel filter? How much fuel is there in the tank? Is there signs of diesel in the engine oil?

Click to expand...

Ratty
Autologic.
Fuel pressures fine, 4 bar at FPR, 2 new filters, 1/2 a tank, no diesel in oil.
thanks

foss said:

Ratty
Autologic.
Fuel pressures fine, 4 bar at FPR, 2 new filters, 1/2 a tank, no diesel in oil.
thanks

Click to expand...

Although not impossible I would have thought it unlikely that the injector/ECU harness's are to blame. The oil usually gets to the ECU and the engine still runs Allbeit lumpy. You say that the oil didn't reach the ECU in yours AND you have changed the injector harness and yet yours doesn't run full stop. Do the connections show signs of oil contamination? The wires running down through the loom are obviously insulated. Only the ends near the plugs aren't.

ratty said:

Although not impossible I would have thought it unlikely that the injector/ECU harness's are to blame. The oil usually gets to the ECU and the engine still runs Allbeit lumpy. You say that the oil didn't reach the ECU in yours AND you have changed the injector harness and yet yours doesn't run full stop. Do the connections show signs of oil contamination? The wires running down through the loom are obviously insulated. Only the ends near the plugs aren't.

Click to expand...

Yes there is oil @ the ecu plug end & on most of the plugs at the other end of the harness, although they have not all been pulled off as there are about a dozen i think.
The tech said that it would cause non starting as well as start & misfire...

foss said:

Yes there is oil @ the ecu plug end & on most of the plugs at the other end of the harness, although they have not all been pulled off as there are about a dozen i think.
The tech said that it would cause non starting as well as start & misfire...

Click to expand...

If there is oil at the ECU end then yes it is both possible and likely. I thought from your previous post that the oil hadn't reached the ECU.

ratty said:

If there is oil at the ECU end then yes it is both possible and likely. I thought from your previous post that the oil hadn't reached the ECU.

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Sorry Ratty, Ive typed this out so many times to different people I forget who Ive told what!
Yeah ECU end but not in ECU, only on red plug-LOTS.
ECU is away for test @ TD5 Alive too...

foss said:

Sorry Ratty, Ive typed this out so many times to different people I forget who Ive told what!
Yeah ECU end but not in ECU, only on red plug-LOTS.
ECU is away for test @ TD5 Alive too...

Click to expand...

Sounds like it is oil contamination causing your problems then.

UPDATE-
ECU is back from Gary @ TD5 Alive-tested as no signal to injectors 1,2,4 & 5.Although passed the "click" test on Autologic.ECU has been replaced with a clone.The problem has been caused by severe oil contamination in the engine-ecu loom which is being replaced also.
Will let you all know IF & when it starts!
Foss

I picked my car up tonight.The ECU fix & Harness seem to have sorted things, however I am slightly lacking power through the gears-about 90% of what I used to have I reckon.Apparently this is often an issue when the injector washers are changed on "black top" injectors, & the power will return after a couple of hundred miles.
Starts like a dream , everything is A1 except the marginal power loss-but for now, I can live with that as my bank balance is pretty desperate now!!!
How is yours?
Paul

hi so you sorted it with the harness ??? what did you do to the ecu thanks let me know ultra150

Ref thread started by ULTRA150..


Hi mate
I sent it to Gary Wood @ TD5 Alive, google it & you can get contact details off their site.
My ECU was only sending a signal to Inj 3, not 1,2,4 & 5!! The ECU was spiked by the oil in the main harness.The car passed an injector click test on Autologic too, so that obviously isnt always a reliable route.
I sent it off on a friday, he called me Monday & I had it back Tuesday morning-top service.
Basically, he takes an ECU he has already repaired & tested & knows is 100%.
Then he takes off the Alarm/Immobiliser & injector codes off your ECU & transfers them on to the reconned ECU,basically cloning the knackered one.
It was £80 for the initial test & £150 for the replacement ECU.
I checked my old harness when it was taken off-oil in all ends of the cables, even to starter motor connection.
Plugged the whole lot in & it started like it was a new car-I barely have to turn the key, no ****!
My mechanic reckons its running on about 90% of the power I had before it broke down,sometimes its a bit like trying to drive in 4th gear at 30mph if you know what I mean, but Ive found thats normally on a hill when Im not giving it enough throttle; but to be honest mine was never that quick & its often the case if you have black top injectors rather than the later green top ones that when youve also changed the injector washers, the power drops slightly & "should" return after a few hundred miles.Ive driven it all weekend & done 200 miles since yesterday morning.No misses & starts on the button.Went off road today & coped with everything I threw at it as it used to.
Pleased its all sorted-well til the next thing goes wrong!
Let me know how you get on
Foss

ok thanks foss will do

I have followed your thread with interest, oh boy, with a lot of interest. I have the same problem and I have replaced injectors, and second set of washers, new fuel pump, new filter housing, no leask in fuels lines etc.. I havent messed around with the ECU end of things.
Anyhow, I am curiuos if your Discos problems are solved. Would be great to hear.
An exceedingly, frustrated TD5 owner.

hi yes new engine harness and ecu did the trick in the end and injector seals and washers.

Yep same as, still all good (where's some wood?!)

Good luck!