Non starting 300tdi

[nas90tdi]

I flew to Texas to help my nephew get one of his projects back on track. This was a running 300TDi he removed 4 years ago and put on a galvanized chassis.

It has sat for that time. When I arrived I wanted to get the engine up and running before we started forward. It will not crank.

It's a 300TDi non egr with no anti theft system.

Things I have done.

12V inline fuel pump at sedimenter
New lift pump
Replaced old spill rail lines as they were leaking.
Bled all lines
Replaced fuel fiter
Pulled front cover and checked timing. Had to move the pump pulley less then 1/2 a tooth to set baseline to factory
Pulled solenoid and cleaned and tested it, unfortunately I don't have a spare here to test with. I would pull the pin and attempt to crank it ,but I have just bled the new clutch system and don't want it's first test to be attempting to stall an engine with no pin in the shut off solenoid. Considered smothering it, but didn't want to risk pulling trash into the turbo or crushing the intake hoses when killing it that way.

I have the harness and dash in now and am using the ignition switch to crank, but prior to dash and harness I tested with direct power to solenoid and starter relay.

It cranked once briefly but would not rev at all.
Since then it seems to try to crank and exhaust is puffing slightly. Light grey and an occasional puff of black unburnt fuel.

I have clear fuel with no air to filter and to injection pump inlet. No leaks anywhere. I can't seem to get fuel flow to the injectors.

He doesn't have a compression tester handy to check compression and I have not checked the valves yet.

What am I not thinking of here? Bad IP? I keep coming back to that, but I am hoping someone has a suggestion I haven't thought of yet. Its like I am getting no fuel past the IP.

 

[Overlander]

sure sounds like air still in system. no reason to think timing or compression are issues if it ran when it went dormant.

asking the basics since you didn't mention it. did you crack all the injectors and turn it over while cracked? if so, did they leak fuel? all the bleeding in the world won't do you any good if you don't bleed those.

and since everything is on the table as suspect, any chance you put that 12v pump on backwards?

 

[nas90tdi]

Yes, it has been broken loose all the way to the injectors. That is why I am saying I have no fuel to the injectors. That is what is stumping me and making me suspect the IP. I also agree about the compression and timing, but, it was a last ditch effort since the usual things weren't working. I don't actually suspect engine issues either because it was a good running engine before removal, but my nephew had replaced the timing belt after removal so, felt it was worth a look under the cover.

And, no 12v pump is oriented correctly.

I keep saying air in the system to, but I have done about 50 times more then I have ever even bothered doing to bleed one. The no fuel at the injector itself is what concerns me. I suspect bad IP and it doesn't build pressure except occasionally and pops an injector.

However, I also feel like with the 12v pump I should still be able to bleed it to the injector.

 

[Overlander]

does sound like IP blockage if you are confident you have good flow up to solenoid and you are certain it is working

 

[Roverman2010]

Take the guts out of the stop solenoid, see if that makes a differance

 

[nas90tdi]

Getting close to that solution. It will start with difficulty using a gas soaked rag to get in going. But, it will only idle at low RPM . No throttle response at all. Tried running it on new diesel since we know that the fuel is old. No difference. Solenoid could be not pulling open fully. I am not getting anything like the amount of fuel at the injectors I should.

 

[RDavisinVA]

Verify 12V (+) to IP fuel-shut-off
If you PM me, I can give you my number and supply you with a way to get it running.