E320cdi fueling issue.

[tiffyh]

Hello to all, first post having been running 99 E300td for many years with no significant issues 200k due up in 30 miles. Due a glow plug replacement very soon as difficult starting becoming an issue even with improving temperatures in the morning. However---------------------

I have purchased a 2000 320cdi with a fueling issue. The car has 126k and had come in for the injectors to be reseated and re-sealed as the car had suffered the "black death". The injectors were reseated and sealed and the engine restarted and ran under test well with good throttle response.

It then cut out and since then will not restart.
Works completed since non start.
Fault codes cleared down. (None significant to existing faullt)
All nylon fuel lines replaced.
Fuel filter replaced.
Tank drained and fresh fuel added (car had stood for 3 years prior to injector work)
Tank Filter replaced.
Main fuel supply line blown through to tank. (no obstruction).
All fuses checked and cleaned.
Temporary fuel supply hooked up to filter from diesel can and very limited fuel pick up observed.
Air in nylon hose on elbow of line to HP pump not moving under repeated cranking.
No visible leaks and all nylon fuel lines connected correctly

Suspect HP pump but do not have Star test equipment to confirm.

Any advice greatlly appreciated

Many thanks
Adrian

 

[Mickybo]

how many times have you tried to start it? with that many changes it could take a lot of cranking before it bleeds through and starts, I just changed my fuel filter and it took 5-6 attempts before it come back to life

 

[tiffyh]

Mickybo,

Thanks for your response, the engine has been cranked repeatedly and for more time than woulld normally be expected to bleed the system of air.

Adrian.

 

[Mickybo]

is the glow plugs working? though you might be right, does sound like either low or high pressure pump may not be working. Was the engine up to temp before it cut out? just might be a problem with the crank position sensor

 

[tiffyh]

Engine was up to temp and CPS has been replaced (failed to list this in first post).

Thanks again for trying to assist.

Adrian.

 

[tiffyh]

Glow plugs operational.

 

[mersum1es]

Injector leak
Pressure sensor
Pressure regulator

injector leak can be easily DIY tested: http://www.mese.fi/forum/userpix/6563_paluuvuoto_1.jpg

Pressure sensor can be tested by unplugging it (starts in limp mode)

O-rings of the regulator shoudl be checked too.

Fuel transfer pump rarely fails but worth to check?

 

[tiffyh]

Thanks Mersum,

Injectors are not leaking. How does the pressure regulator work? The HP pump is cam driven so I am assuming it will generate high pressure unless it is regulated at it's upper pressure operational end.

We are not generating any fuel delivery, so would it be the pressure regulator stopping this?

Difficult to test pressure sensor as engine not running. By fuel transfer pump I assume you mean the initial small pump on the front of the timing case, this we have tested and is working.

From this you can understand my diagnosis of HP pump, just don't like replacing parts until fault is known.

Thanks again

Adrian.

 

[mersum1es]

Faulty pressure sensor or low pressure value is not allowing engine to start, when unplugging it ecu gets a signal which neglets the pressure value and it starts IF pressure actually is high enough.

Pressure regulator is basically as a pressure relief valve which sets the rail pressure value. It's common issue that o-rings of the regulator also fails, and leak cause the pressure drop. Regulator spool may also jam, slight knock may help...

HP pump may leak internally, it's quite hard to check anyway. There are good threads about changing seals of the hp-pump, done that myself too.

I suggest that you 'd try pull the codes (find someone with star), at the same time you'll able to observe the rail pressure during the start attempt.

Sorry if some unclear writing, couple of beer behind while watching FIN-RUS icehockey WC match

 

[tiffyh]

OK thanks.
I will check out the PR before replacing the pump although I still can't see how the pump would not give fuel pressure even if the regulator was faulty. This pump is giving no or very little pressure.

Will investigate tomorrow when I get back to work and report further.

 

[tiffyh]

Does anyone have Star in the Burgess Hill area of Sussex and would be willing to come and
run test on this one?, Vehicle in Sayers Common. I am just so reluctant to start replacing further parts until we know exactly what is causing the non starting.

Many thanks
Adrian.

 

[E270 Owner]

The injectors were reseated and sealed and the engine restarted and ran under test well with good throttle response.

It then cut out and since then will not restart.

How were the injectors removed from the head ?