If you believe the injectors are good and the injection pump is ok then try disconnecting the low pressure rubber fuel pipe feeding the injection pump . Tie a funnel to the bonnet catch and feed a pipe to the injection pump then put some diesel in the funnel then try starting the engine , if it starts then you have a problem in the fuel supply line , you can do this test in about 5 minutes , dont worry about air bubbles or priming , its not needed . A Euro 3 D5 normally starts very easily and needs nothing like the 2 bar pressure specified for the in tank pump .

Loosing the Plot!!!
 

Well its been 6 months and shes still not running. Admittedly I've been away for a while but we're back to trying to get her started. Everything has been checked,double checked and rechecked. Both my mechanic and I are absolutely stumped. If anybody has any ideas, they would be gratefully excepted.

Injectors Tested
Fuel pump tested
Lift pump replaced.
ECU tested.
Fuel Rail pressure OK
Cranking pressure and Voltage ok
Timing Double Checked - Belt and Head
Sensor Checked
Crank sensor replaced
Wiring double/triple checked.

Just to give you and idea of whats been done and a lot more I've forgot.

Just read through this. Have you read the codes?

You talk about "easy start" is that gas you spray in the inlet? if it runs keeps it running or shuts down when you remove the gas?

Besides all the checking im inclined to think that the damage that the snapping cambelt caused could be in someway related

Hi, your not gonna like this, but, we had a few D5's where the timing belt broke and the cam lobes moved around the main shaft of the camshafts, volvo has a plastic tool with the cam profile cut out of it, you set it to tdc and put this tool over the cam lobe, if it fits, the lobes are in the right spot, if it doesnt then they arent.

try re seating the ECU see if that helps.
mike

Hi OP,

I know this is a very old post but I'm having a similar issue. Did you manage to sort out your car mate?

Thanks

My car is now sorted. The issue I had was...I had not done the priming correctly, therefore there were lots of air in the fuel line. I did the key On and OFF cycle for over 20 times (as advised by Volvo) and then car started straight away.

If you remove any fuel system line (like a hose or a banjo bolt or high pressure pipe etc), it sucks air in then stops sending fuel to common rail. When you turn the key to ON (ignition on) and if you have air then you could hear fuel flowing in there inside the fuel filter housing under rear passenger seating location. So you have to prime until you hear nothing but whining noise. This is achieved by above method, ON and then OFF

Cheers

There is a very handy video on you tube - ''XC90 D5 185 priming fuel system after repairs'' from a Yorkshire chap who explains exactly what to do, in that scenario of engine not starting after disconnecting fuel lines or changing the swirl flaps.