Originally Posted by sr20goofus

First post here after lots of reading and testing I am finally giving in and making a post hoping for some help.

2010 X5D 135K Miles

Purchased the car and drove it 30miles home, no issues besides a few known CEL lights for glow plugs and a DEF tank level issue.

Started my DPF, SCR, EGR and Swirl Flap delete.

The entire delete process was a bit time consuming, but no abnormal hiccups of any kind. I removed both of the DEF tanks as well.

Removed:
DPF
SCR
EGR
DEF Tanks
2 rear NOX sensors
Swirl Flaps
Swirl Flap Actuator
Glow Plugs
Glow Plug Module

Installed:
Buzzken Downpipe Kit
EGR Block Off plate
EGR Race Tube
Swirl Flap Delete Plugs
New Glow Plugs
New Glow Plug Module
New Thermostat
Malone 2.5 Tune flashed to ECU w/ Flashzilla

When removing one of the glowplugs the tip broke off, common issue. So I removed the cyl3 Fuel Injector and used a magnet and boroscope to find the tip and fish it out through the fuel injector hole. Reinstalled the fuel injector and replaced a metal fuel line that was corroded.

Time to start the car. No luck, just the starter motors.

Charge the battery back up thinking that is causing an issue. Still no luck.

Removed the intake manifold again and bleed the fuel system, to get fuel up to each injector. Still no start.

Inspected all connectors, only ones left were from parts removed.

MAP sensor was coked up pretty good, so I cleaned that up and out. Still no start.

Used a diagnostic tool to verify fuel pump operation during start.

ECU was never removed so those connections are not an issue. The fuel rail sensors were not removed so neither of those were forgotten.

I am at the end of my rope trying to figure this out. If todays final attempts at reading fuel pressure during an attempted start doesnt tell me anything I plan to send my ECU to Malone for testing.



Does anyone have any suggestions or pointers for the work done and troubleshooting performed? I would love to get this car on the road, its just kicking my butt now.