Mk7 2.4 rwd non starter!!!

[1888]

there does seem to be some similarities with the datsun lol

Think they call that rust

[SteveJeff]

there does seem to be some similarities with the datsun lol

Think they call that rust

I was lured in by the lack of rust on this van....... totally overlooked the fooked engine side of things lol

[SteveJeff]

Hi folks,

I have had another look at my van today and had a bit of help from a friend so that i can see what is going on whilst trying to start it....... there appears to be lots of air in the fuel system. I changed the Fuel filter again but still the same. I put a pipe from a jerry can through a hand primer pump ( rubber squeezy ball type thing ) onto the high pressure pump pick up pipe and then a pipe from the leak off pipes back to the jerry can. I pump the hand primer to get rid of most of the air and then tried to start the van. It would still only start with brake cleaner but it seemed to produce quite a lot of air through the return pipes but also the fuel pump didnt seem to be sucking the diesel through from the jerry can...... am I right in thinking that the high pressure pump is screwed ? and could this have been the reason why it didnt like starting once it was hot ?? or could it be the valves on the pump as opposed to the pump itself ?

Anyone know how difficult a job this is on a 2.4 rwd and also if it is the pump will it need coding or teaching in before it will work ?

thanks again for any help or information given

[TheCake]

id guess that changing any fuel delivery parts its best to do learns after so as to not encourage any issues due to changes in fuel delivery rate and such

[knobby1]

Hi folks,

I have had another look at my van today and had a bit of help from a friend so that i can see what is going on whilst trying to start it....... there appears to be lots of air in the fuel system. I changed the Fuel filter again but still the same. I put a pipe from a jerry can through a hand primer pump ( rubber squeezy ball type thing ) onto the high pressure pump pick up pipe and then a pipe from the leak off pipes back to the jerry can. I pump the hand primer to get rid of most of the air and then tried to start the van. It would still only start with brake cleaner but it seemed to produce quite a lot of air through the return pipes but also the fuel pump didnt seem to be sucking the diesel through from the jerry can...... am I right in thinking that the high pressure pump is screwed ? and could this have been the reason why it didnt like starting once it was hot ?? or could it be the valves on the pump as opposed to the pump itself ?

Anyone know how difficult a job this is on a 2.4 rwd and also if it is the pump will it need coding or teaching in before it will work ?

thanks again for any help or information given

If you're still getting air in the system, she'll never run properly, you've eliminated the filter as a source of air ingress, the only other place it can get in are the injector leak-off pipes and O-rings. The TDCi pumps themselves rarely fail. If it does turn out to be the pump, they're plug n play, no coding required.

Lord Knobrot

[SteveJeff]

Thanks for the replies everyone, I have not been able to get back on the van for a couple of weeks but will hopefully be back on it soon. I will update with any progress. Thanks for all the input and information given.

Nobby,

I have ordered injector leak off o-rings and new copper sealing washers as I have already messed around with the injectors so wanted to replace everything that had been disturbed!! Fingers crossed I can actually get the thing running again very soon

Thanks for your time and information.

[knobby1]

Thanks for the replies everyone, I have not been able to get back on the van for a couple of weeks but will hopefully be back on it soon. I will update with any progress. Thanks for all the input and information given.

Nobby,

I have ordered injector leak off o-rings and new copper sealing washers as I have already messed around with the injectors so wanted to replace everything that had been disturbed!! Fingers crossed I can actually get the thing running again very soon

Thanks for your time and information.

You'll need the injector clamp bolts too, they're stretch bolts and single use. If torqued to spec again, there's a good chance they will snap.

Lord Knobrot

[SteveJeff]

Cheers Nobby I will get some on order lol
Thanks for the heads up

[Uncle_Fester]

I'm no mechanic, however I had a Renault clip 1.4 dci that did the same thing, had lots of "experts" look at it, did crank sensor etc.
Would only start with easy start...
Sold it to a couple of gypsies who towed it away, and I asked them to let me know if they every found the problem.
Two days later they called to tell it was injector no.2 that was sticking open (dribbling fuel) so that the rail couldn't pressurize.
Easy fix for them, but not for the "professional diesel specialists " apparently.
Saw them driving it around a couple of weeks later.
Anyhoo, it could be a dodgy injector.
My two peneth

Fester

(Mk7 2.2tdci jumbo highroof twin wheel 17 seat minibus.)

[SteveJeff]

Thanks Fester

I am in the midst of trying some other stuff first as this only starts and runs on easy start as soon as that is used up it won't run at all but it was running sweet until it got warm and then wouldn't restart and now won't start at all other than the dreaded easy start!! I will keep the injectors in mind though if where I am at fails lol

Thanks
Steve

[SteveJeff]

Right guys,

A quick update, I have changed o rings on injector return pipes, fitted a new genuine fuel filter, new scv, new prv, new egr valve, new inlet manifold gaskets.

According to FORscan I have 7000kpa fuel pressure during cranking, the bloody thing still doesn't start, can't do a pump learn as it needs to be running...... any suggestions guys or am I missing something really stupid ? Is that fuel rail pressure enough during cranking ?

Thanks

Steve

[knobby1]

Right guys,

A quick update, I have changed o rings on injector return pipes, fitted a new genuine fuel filter, new scv, new prv, new egr valve, new inlet manifold gaskets.

According to FORscan I have 7000kpa fuel pressure during cranking, the bloody thing still doesn't start, can't do a pump learn as it needs to be running...... any suggestions guys or am I missing something really stupid ? Is that fuel rail pressure enough during cranking ?

Thanks

Steve

She needs about 300bar (30,000kpa) during cranking. Idle FRP is 230bar +/- 10%. 7000kpa (70 bar) is nowhere near enough.

Does she start with a sniff of easy start..?? Might have air in the system. Did you fill the filter with fuel before fitting..?? If not you've pretty much filled the system with air.

Lord Knobrot

[SteveJeff]

Yes she starts with brake cleaner no problem. I did fill the original fuel filter to the brim and then it broke down after about a 10 minute drive. ( Pattern filter ) I have since changed to a genuine filter and filled to the brim but still won't start on diesel. It won't keep running after brake cleaner has dispersed.

What would be the best way to clear air if it is air in the system, I have a small 12v fluid pump if that will help

Thanks

Steve

[knobby1]

Yes she starts with brake cleaner no problem. I did fill the original fuel filter to the brim and then it broke down after about a 10 minute drive. ( Pattern filter ) I have since changed to a genuine filter and filled to the brim but still won't start on diesel. It won't keep running after brake cleaner has dispersed.

What would be the best way to clear air if it is air in the system, I have a small 12v fluid pump if that will help Thanks Steve

Mk7's are self bleeding....unless air is being introduced from somewhere else....leak-back lines and O-rings ok..? Is the PRV leaking back to tank..?? Pop the PRV leak-back line off and see if there's a silly amount of fuel coming out during cranking, it can be wet but no flow or dripping....if there's flow, it will be blown/broken as they require ~1600bar to lift the valve off the seat.

Failing that, remove the SCV electrical connector and crank it over...they default to full open so you should see plenty of pressure.

Lord Knobrot