05 2.0td fwd Transit non start

[Stormdog]

Having repaced a gearbox and clutch/flywheel on a customers 05 plate fwd tranny, she's now refusing to start and acting like she's out of fuel. i.e starting then immediately cutting out. Replacd crank sensor just in case it was knocked during gearbox change but no help. Connected to Snap ons Verus and cant find anything wrong with ecu or systems. Even checked thru security systems and nothing shows up. Only thing i have done untoward was to reconnect battery briefly while parking her up and waiting for gearbox to arrive to put the window up.
Am i missing something really obvious???

[MrMPuk]

Dunno if it's the same on the FWD but RWD speedo sensor plug and crank sensor plug are the same and often connected back up incorrectly.

[Stormdog]

Thanks but warned about that one, the fwd wiring doesnt allow you to mix them up.

[Stormdog]

realised today that theres a vdo speed limiter fitted, does anyone know if this needs to be set up with new gearbox? i.e coded?

[winterheating]

with it starting then cutting out, that indicates crank sensor fault.
check the wires havnt been trapped inbetween bellhousing and engine.
you should be able to check crank sense by your reader, or if not you can check it from the cluster diagnostic mode.

wich engine is fitted are the pickup teeth about 10mm wide or 20mm wide

[Stormdog]

Its an ABFA engine and i stupidly never checked the segments for the crank snsor, only checked to make sure the clutch fitted and the bolt pattern and starter ring gear were the same. I will take out the crank sensor on monday and see if i can check the segment size thru the hole in the box. If i have fitted the wrong flywheel,is there a way i can leave it in and change a setting in the ecu to allow it to work?
thanks

[winterheating]

it may be easier to check by removing starter motor. did you push new crank sensor right down

[Stormdog]

thanks for that, starter sounds a better bet! and yes i did push crank sensor right down and tightened bolt right up.

[winterheating]

how did you take box out front end off or engine bed out was fuel supply interupted

[Stormdog]

I dropped the subframe on the gearbox side and removed box. Never touched the fuel supply or removed anything from the engine. Checked the fuel filter yesterday and it was only 3/4 full. topped it up and towed the van to try and start it. No joy towing but i did get the management light flashing when it was being towed. One thing i did notice is the rev counter jumps up to 3 or 4 grand when we are trying to start it and seems to stick there until you turn the ignition back off.

[MrMPuk]

Don't try and tow start it, you will cause more damage. Sounds like you may have trapped the wires for the crank sensor.

[Stormdog]

I have not trapped any wires, there is nothing obviously wrong.

[Stormdog]

Well i am a little embarresed! When i installed the new flywheel, i checked the diameter, the fitting to the crank, the clutch fitment and even the ring gear was all the same...... But neglected to check the segments for the crank sensor pick up! I removed one with large segments and stupidly refitted one with small segments! So the riddle is solved to the cost of me having to remove said gearbox and flywheel and replace the flywheel with the correct one! A job for tomorrow i think!
Many thanks to all of you who took the time to throw me some ideas.
Ian

[winterheating]

Well i am a little embarresed! When i installed the new flywheel, i checked the diameter, the fitting to the crank, the clutch fitment and even the ring gear was all the same...... But neglected to check the segments for the crank sensor pick up! I removed one with large segments and stupidly refitted one with small segments! So the riddle is solved to the cost of me having to remove said gearbox and flywheel and replace the flywheel with the correct one! A job for tomorrow i think!
Many thanks to all of you who took the time to throw me some ideas.
Ian

so that one is for a tdci, or mondeo tdci.