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Hmmm I've only just realised you are the guy who is swapping from TDi pump to TD...! I've only done the swap where the TD pump came complete with gear, and without looking closely they both looked the same. It wouldnt surprise me however to find that the keyway is in a different position...

Yes you could line it up 180deg out, but you ought to get fuel at the injectors nevertheless.

Try centre console just under the handbrake / behind the shifter.

It's nothing special other than a EP90 but MUST be the limited slip flavour, often signified by 'LS' . EG EP90LS SAE90LS 85w-90-LS etc.

A Maverick of this year and from what the OP is saying that he has a Cam sensor on the timing case means he will have the Zexel / Hitatchi fuel system.

Very simple really if it has the advance solonoid. You want B+ for the run solonoid live all the time the key is on, from the disconnected ecu multiplug, and a B+ from the starter solonoid live only when cranking to the advance unit. Ensure the engine itself is well earthed (check the strap)...

Can you take a pic of said pump and pop it on please. There are two flavours it would seem, one with electric advance solonoid and one without...

You have a fuel supply issue, no anything with the Turbo , so step away from that area. Change the filter and check for leaks / air ingress.

Not that I am aware, but it would be nice if there were!! MIJ Performance, pleck road walsall did my centre section and tail in 2.5", and I had a local agri engineers make up the elbow and front pipe in stainless from a removed stock downpipe.

So will it fire up with a jump pack when hot? Will it bump start when hot? How fast is it spinning over on the starter when hot? I dont think we are getting accurate symptoms on this....

The 2.5 manual has a towing limit of 2000kg for a braked trailer or donkey carrier. Both diesels are rated at 2200kg. The pre 2004 does indeed use exactly the same selectable 4wd system as the later one, there are 2 square buttons on the dash instead of the rotary knob. I would definately get...

Do you have any motion from the tacho during cranking with it hot? You have all the symptoms of a dying crank position sensor. Method of failure is little or no output when hot, but fine when cooler. As someone said, cool it off with an airline, or freeze spray to test.

What brand is that?? Presumably for the pilot bearing, friction disc, pressure plate, and release bearing ?? Personnally i would only ever fit a LUK or a Delphi one.

An example of a 12degC cold start without the glowplugs from my truck this morning. <iframe width="425" height="349" src="http://www.youtube.com/embed/l0InTI_9pRs?hl=en&fs=1" frameborder="0" allowfullscreen></iframe>

Agreed, the stock elbow and downpipe is a huge restriction, even on a standard motor.

If the rpms stay constant then the ECU isnt receiving any speed signal from the gearbox sensor, so you'll need to investigate more there. Your speedo will come to life then. LCD panel just requires resoldering, once you have the instruments out of the dash, it's literally a 30min job...

LCD will be suffering from dry joints and want re-soldering , speedo could either be the head itself -again dry joints- or a bad connection at the gearbox speed sensor. If you allow the truck to roll forwards with engine at idle, does the idle rpm's jack up when the speedo is dead???

Could you say what exactly is up with the speedo and mileometer please. If the LCD is displaying rubbish, this is easily fixed. Is the speedo intermittent or completely dead?

Drop links and bushes !!!!!!!!!!!! Rusty fuel pipes. Clutch flexi hose bursting. clutch damper rusting. Cheap fuel filters sucking air. Glow plug power feed breaking off. Lazy starters. Poor battery connections giving poor starting. Dead MAFs Worn out clutches (££££ to change) Grumbly back...

Bosch or Beru in my opinion are about the bst quality and have a good lifespan. Are sure you have actual problems with the glow plugs or the controller / wiring? At the morning temps we have at the moment, (15-18degC) it should start WITHOUT pre-glowing after about 5 seconds of cranking. This...