Non starter but with a difference!

2000 diesel, year 2000. Long post but gives all info in one go...hopefully.



Car had broken down and was throwing various codes, eventually injector pump was diagnosed as failed. Pump was rebuilt and fitted, eventually got the air out and the engine started and run perfect. Car idles perfect, drives perfectly, put your foot down and really flies, not a puff of smoke, no lights on dashboard, no codes stored anywhere (Autocom), so in theory all is great except when you switch off and restart after a certain period of time.



Switch off and restart is instant, you can switch off and restart without any hesitation 50 times if need be but, if you leave it for more than around 30 seconds it will crank for ages before starting, hot or cold, when it does eventually start it runs rough for a few seconds with a shedload of grey/blue smoke from the exhaust.



I know that the glow plugs are not totally necessary for starting but have replaced all four anyway just for the record as no4 is a RPITA when the pump is in.



Once started you can repeat the start/switch off/start over and over with no hesitation. My first thought was air, the pump by the filter often failing going by past experience with other vehicles, so I switched off the engine and immediately clamped the fuel line as it enters the (new) fuel filter. Left the car 20 minutes released the clamp same non start problem.



Next tried switching off and leaving for a few minutes, then pumped the bulb until hard, again no starting unless cranking for ages repeat misfire/smoke.



I would have said the fuel is running back to the tank if I knew no better but the clamp throws that idea out of the window. During the cranking when it is not starting there is a definite attempt to start and really does sound like fuel starvation. Leak off pipes have been renewed, including the run to the pump, no visible fuel (or any other liquid for that matter) leaks anywhere.



My next plan is to try clamping the inlet rubber pipe where it enters the pump, to see if that helps, I am now thinking a one way valve in the reconditioned pump is not right somehow? I am almost 99% sure it is air related but....



Any thoughts?



Something else I would like advice about is the immobiliser, it seems to be coincidental that the time from starting instantly to non start seems to be tied in with the immobiliser light coming on or very close to it but, I was under the impression on this model the immobiliser controls not only the injection but also cranking, is it possible that the immobiliser can allow cranking and not starting?



The red LED when locking the car, does the normal flash fast, then slow and stays slow and steady flash nothing new there. Press the unlock button light goes out and doors unlock, get in switch on ignition all lights present including the two yellow pump and OBD lights, crank engine red light still out no start.

If the engine is running and you switch it off, after around 15 seconds or so the red LED flashes, put the key in the ignition and turn on and the red light goes out, the engine may or may not start.



Next week it is going to the diesel shop but am trying to save the trip if possible.



Any thoughts and thanks in advance.





Dave

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