Advice needed - D22 Crank sensor contacting

[Richeh7]

Hi all, I’m in need of some advice as I’m left a bit stumped. So I carried out an engine change/rebuild on a D22 Navara 2004 with the DDT engine. Had to swap the blocks due to a fault. The new block came with a flywheel on that that appeared to be in good condition so I decided to use it.

The assembly went smoothly and the Ute starts and idles fine but I noticed the tachometer stopped reading shortly after start. Pulled the code and it was the Crank Position sensor, it was cut on the tip so I replaced it with another one, because I thought it was damaged on reassembly (P/N RS-327 or 23731-WD000) and the issue came through again. It seems as if it’s sitting too close to the flywheel and being cut. Any ideas on what’s going on?

Any advice that can give me some guidance on where to start looking or things I haven’t thought of would be much appreciated.

 

[tweak'e]

not sure if its just the lingo or somethings been mixed up.

the crank sensor runs off the front pulley, not the flywheel. they are also adjustable, specs are in the book.
if in doubt post some pics up of the sensor location etc.

 

[Richeh7]

not sure if its just the lingo or somethings been mixed up.

the crank sensor runs off the front pulley, not the flywheel. they are also adjustable, specs are in the book.
if in doubt post some pics up of the sensor location etc.

Unsure, the sensor that is contacting the flywheel (On the back of the block & connects to gearbox) the faulty sensor is located on what looks like a spacer plate between the engine & Gearbox and feeds into a hole over the flywheel and looks like it takes a reading off of the teeth that the starter uses? Unless the sensor is used for something else because i am unable to locate one on the front pully. How are TDC sensors usually adjusted?

Thanks for the reply man, i appreciate it

 

[tweak'e]

ok. i think we need to see what ute you actually have.
the only D22 engine with a crank sensor on the flywheel is the later common rail yd25 engine 2008 onwards.
2004 4wd will have the zd30, which has the sensor on the front pully.

unless you have the 2wd that came with yd25. i'm not 100% sure on it. the book says sensor on the front pully but shows a sensor in the block in the diagram.
if you have the yd25 non-common rail engine, check the block you got is the right one. i'm not sure what the differences are with the later blocks.

 

[Richeh7]

ok. i think we need to see what ute you actually have.
the only D22 engine with a crank sensor on the flywheel is the later common rail yd25 engine 2008 onwards.
2004 4wd will have the zd30, which has the sensor on the front pully.

unless you have the 2wd that came with yd25. i'm not 100% sure on it. the book says sensor on the front pully but shows a sensor in the block in the diagram.
if you have the yd25 non-common rail engine, check the block you got is the right one. i'm not sure what the differences are with the later blocks.

It is a 2.5 2WD 2004 have had some issues with identifying the engine, as from all its paperwork its suppose to have the YD25DDTI engine installed, but it appears to the the YD25DDT? I might be mistaken this is just what i have pulled out of other forums. The only differences that i have really come across between the two is that my engine (DDT) is a mechanical fuel pump & Cylinder Head set up like where the injectors insert.

I believe i have the NON-Common rail engine as the mechanical pump separates it off into 4 pipelines that go to each injector, and as i found while bleeding the lines they all get pressurized at separate intervals.

Back to the original fault, i can confirm that there is 100% no TDC sensor on the front pully, although i really wish there was. I have been thinking of switching back to the old clutch on the off chance that they are a different diameter . Unless i can get some sort of way to adjust the TDC Sensor on that flywheel. I have thought of just using shims to space it out to get the correct 1mm +/- 0.4mm spacing.

 

[tweak'e]

i wonder if you got a common rail block and flywheel and the flywheel is a tad different.

pull the gear box off and check the flywheel and compare it to the old one or get one of the common rail crank sensors and see what the difference is between them.