I'm starting to think I've made a big mistake getting this thing. I bought it thinking it simply needed injector sleeve seals but it turned out to be far more serious. I replaced the seals but it went bang after 200KM. Heaps of diesel in the coolant and vice-versa so I took the head off and got it tested, it failed, so I replaced it. Since then it has been running really well - heaps of power, very smooth, no smoke etc.
I've done about 800KM since then, and today after driving 100KM or so it suddenly lost about half of its power. There were no weird noises, it was like I had gently lifted my food off the accelerator slightly. I reved it a bit, still seemed weak. 10 seconds later the engine cut out like I had turned off the ignition, 15 KMs from home. No check engine light either. It didn't seem to matter how long I cranked it for, it wouldn't even cough. I don't have access to a Tech2 either which makes this even more painful to diagnose.
Things I have checked so far:
Pumped the manual pump a few times.
Emptied fuel filter into a bottle - it was about 50% coolant. f**k. I replaced the filter when I did the head and it was 50% coolant then too so it looks like I'll have to drain the tank (I didn't drain the tank after I replaced the head so thankfully it would be old coolant ).
Primed fuel system again - still nothing.
Confirmed hoses to the manual fuel pump were the right way around.
RACQ guy tried his Snapon OBD diagnostic tool but it showed no errors.
RACQ guy also tried ether in the intake - it briefly fired as expected but that's it.
Checked all fuses with multimeter - all good.
Swapped out ECU relays with other identical relays.
Cleaned ECU connectors, injector loom connectors and cam angle sensor connector with contact cleaner.
Swapped over batteries as the constant cranking couldn't be good for it.
Things I'm going to try tomorrow
Hook up hose to either outlet side of fuel pump or fuel return line and make sure the fuel pump is actually pumping.
Paper clip in ODB connector trick to get any MIL/CEL codes.
Empty fuel filter again - if its all coolant then I guess I have half a tank of coolant :-/
Could it be the ORPS? Is there any way to check without a Tech2? I'm sure I read something somewhere about disconnecting a wire.... edit: found it - I'll do this test first.
I've given up for tonight as it sucks working on this while its on the road, but does anyone else have any ideas for me to try tomorrow? I'm really trying to avoid taking this to Holden as I've already got some expensive things to replace in the near future (needs a new clutch/flywheel and I've got a new drag link + tie rod ends already in the post).