Fault codes after Glowplug warning

[OldskoolUpNorth]

Morning guys,

After my last thread about glowplug warning light and Enzo's answer, I picked up an ELM327.

The following codes have come up....

Code: P0251 - Injector pump fuel metering control malfunction
Code: P0405 - EGR Sensor A Circuit Low
Code: B1359 - Ignition run / accessory circuit failure. Instrument cluster.
Code: P1211 - Open TP sensor circuit. Powertrain Control Module.
Code: P2291 - Injector control pressure too low during engine cranking

Im waiting on a leak back test kit to arrive as this seems a good place to start.

Sounds like I may also have a faulty EGR, accelerator pedal and fuel pump from what I can gather.

Can anyone suggest a starting point for the other codes, B1359 & P1211?

Cheers,

Neil.

[Graham Taylor]

I'd wait for the leak off test then replace any/all injectors. Clear all codes then get them read again. Often one issue can cause another error to register.

[OldskoolUpNorth]

Cheers for the advice Graham.

Not done the leak back test yet as the British summer rain is keeping me indoors but I'm guessing it will be the injectors at fault.

So, does anyone know if I need to relieve the pressure on the injectors before removing the fuel line to each? They're delphi on a 90ps tdci euro 3.
And is there a process I need to follow to bleed them up after replacing them.

Thanks in advance.

Neil.

[Enzo200500]

I think it is the same engine as mine!

Pull off the return pipes from each injector. Block each one to prevent air ingress.

Connect your four identical length clear pipes to the injector outlets and start the engine!

You do not need to disturb the high pressure side, unless changing the injectors.

There is a time limit on tickover to see how much is leaking off the injectors, then at higher rpm's.

They usually show faulty on tickover!

Dieselboy on here is the man for recon injectors. Good guy to deal with.

[OldskoolUpNorth]

Thanks for the advice again Enzo,

The leak back test was a pure failure.
I couldn't do the full 5 min Delphi test as the bottles were almost full within 30 seconds, cylinder 1 pretty bad and 2 was the worst, 3 & 4 half full.

Changed injector control valves in 1 & 2 as a test but I think the new pressure in the rail has caused one of the other injectors to give up.
Got serious 'knock' and smoking like a steam train ( white smoke that is so its over fueling somewhere).

The head on cyl 3 clamp bolt was already round and the injector in cyl 4 is welded in.
I'll get the slide hammer on 4 next week and see what I can do to 3's knackered bolt head.

Anyone want to buy an 06 lwb tdci 90. Non runner.... going cheap.

Updates to follow.

[OldskoolUpNorth]

Afternoon all,

Time for a quick update.

So far, I've managed to get out injectors 3 & 4 and tinker around so the 'knocking' has stopped and there's a only slight over-fueling (white smoke).
That's down to worn / dirty injectors.

I refuse to pay for new injectors so doing a bit of a work around.
New parts will be coming this week and if it works I'll post the results.

Fingers, toes and eyes all crossed.....

Cheers,
Neil.

[OldskoolUpNorth]

Right guys, another update.

Not a full solution yet but I might be getting there.
Be warned - It may not work for everyone. Or at all....
Does require a fair amount of specialist tools and a few hours time.

Working 1 at a time:
I changed all the injector control valves, these are parts internal to the injector.
A local Delphi service centre supplied these at £60.00 each inc VAT. Apparently many centre's won't supply unless your in the trade.
Cleaned the rest of the injector nozzle parts with carb cleaner - but NOT the solenoid.
Really need an ultrasonic bath but as its only a learning curve on a spare van, I'm not going to spend loads on it.

Started van up but still over-fueling.
Re-entered injector codes to clear the 'Adaptions' that the ECU has learned.

I guess that the ECU learned over-fueling as a result of the amount of leak back I had. Not a lot of pressure in the rail, so longer injector opening time to get same amount of fuel into the cylinder.

Also cleared fault codes, still have 1 for instrument cluster but nothing relating to fuel system.

Has now stopped over-fueling on idle but does on acceleration.
I'll take it out for an hour as the ECU should relearn the fueling needs (I think) but its a spare van and not in use so could be a while before I do.

Cheers,
Neil.