Hi, I've spent all weekend pulling my hair out. I spent 4 hours removing the gearbox and the clutch/flywheel. what a chew on it is getting the box out! i fitted a new sachs DMF and clutch exactly the same as the one that came out. the new flywheel only went on in one position where all the bolts lined up so i know that that's fitted correctly. i also changed the slave as its good practice. after an hour conventionally bleeding the clutch and getting no where i got hold of a pressure bleeder which bled the system in literally seconds and i thought all was well until i tried to start the car. it turns over and spluttered into life a few times but only for a few seconds.

i checked all electrical connections and found i forgot to plug the air flow meter back in, tried starting it again, still no luck. had a word with a proper car mechanic as i'm a mechanical engineer and work on factory machinery so don't really have much experience in fault finding on cars. he said that the crank shaft position sensor is critical to the starting of the engine and on my car it reads its position off the flywheel which sounds right as i replaced the flywheel so the air gap between the sensor and flywheel may have changed some what. I googled the "air gap" and found nothing, tried ringing the stealership and they wouldn't tell me anything. they told me to bring it in to which a replied how can i bring it in it wont start! haha anyway i decided to remove the sensor and found it was scratched and damaged so i a rang the motor factors and got a new one delivered within the hour and fitted that and still no luck.

on the dash the red warning light (!) is on and wont go off. I've got a guy with a fault code reader coming tomorrow, see if i get anywhere with that

I've also checked all the earths and also tried adding an additional earth using a jump lead The car is a 56 plate focus 1.8 tdci, any help would be MASSIVELY appreciated. thanks.