E320cdi S210 non start!

[Richard1973]

Left work tonight and the car was running great. 60 mile run to Macclesfield, stop, 60 mile run back to Burton. No problems apart from the smoke under load but think the EGR needs sorting. Now home and it won't start! Turns over fine but not firing. Will look more in the morning, but any suggestions on where to start?

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[bob6600]

Check all fuel lines/leak off pipes from the injectors, pipes to and from HP pump and fuel filter. And of course from the rail. If no evidence of leak, let it cool down and try it again. Could be the CPS

 

[Richard1973]

I did think of just trying it in the morning! Is CPS easy to get at? No means of diagnosis either. Trial and error it will be!

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[Richard1973]

Checked it this morning and fuel to pump, up to rail and to injectors when cranking. Resorted to a squirt of easy start and it fired straight up. Suspect it's got an injector on the way out or something else causing a fuel pressure drop. Starting ok now. I did notice while the covers were off that the swirl flaps seem to be disconnected. Going for a STAR diagnostic session on Monday to see if I can find the problem

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[ringway]

Sounds like fuel in the plastic air lines to me.
I had this problem until getting the chance to fix last weekend. 6 O-rings will cost around £10 from the dealership.

The problem I had (I had replaced the 3 plastic lines on a previous 320CDI) was disconnecting the lines without breaking the catches, which were brittle due to age.
I broke 2 but I, erm... superglued the pipes back on and they won't come off in a hurry. It was bank holiday Sunday...

Also, I made sure that the fuel filter housing was correctly screwed on.
I put plenty of grease around the thread and tightened as much as I could by hand. 25nm if you have something large enough to grip it.

This problem had been going on for months, especially when cold, and most times it would eventually start by continually cranking for 40-60 seconds, but after calling out the RAC for the second time, I thought I'd better sort it out.
Starts on the button now and its harder to get the ECP warning if I floor the car, because now it receives fuel instead of air and fuel!

If it is the HP pump, you will be able to see or smell diesel. The seals on the pump weep when cold, but re-seal themselves when they get warm.

 

[Richard1973]

Now had it on STAR. Only faults showing are No.5 glow plug, which could be the starting issue, a stored fault of a fuel rail pressure monitor control variation, and the EGR is showing too low for recirculation. At least I have a place to start now!

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[bob6600]

Glow plug won't stop it starting but the fuel rail pressure will

 

[Richard1973]

That's what I thought, but the fuel pressure isn't an active fault. Codes were, P1481-016, P1423-032 and P1187-032. Can you shed any more light on these?

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[Richard1973]

Going to tackle the glow plug and EGR this week. I have been advised to make sure the engine is hot before trying to get the glow plug out. Would I be better out sourcing this job? At least if a garage snaps it they can fix it! EGR should be ok to do. Going to try cleaning it to start with. Any recommendations on best method to clean it once it's off the car, and is it worth doing anything else while it's off?

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[a111r]

If they snap it, you'll still pay for the repair (I think..)

Oven cleaner (but don't leave it on too long with Aluminium).

 

[Richard1973]

If they snap it, you'll still pay for the repair (I think..)

Oven cleaner (but don't leave it on too long with Aluminium).

Someone else said oven cleaner! Got all week to mess with it so will see if I'm feeling like tackling the glow plug! I think part of the problem is the car was used on short runs and had a faulty thermostat, so never got up to temperature. Hope that by cleaning out the EGR it may improve the black smoke under load.

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[a111r]

Someone else said oven cleaner! Got all week to mess with it so will see if I'm feeling like tackling the glow plug! I think part of the problem is the car was used on short runs and had a faulty thermostat, so never got up to temperature. Hope that by cleaning out the EGR it may improve the black smoke under load.

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Same boat as me. Mine needs a good clean.

I've also got one failed very stiff, GP. It's been fed lube and tentatively checked a few times...but still stiff. Not worth risking it snap, IMO. The previous two came out very easily

 

[Richard1973]

Got the spanners out this morning, but the EGR is not a driveway job. Looks like you need access from below to get at the support bolts and the intercooler pipe . Think I will get it in somewhere to be done instead.

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[Richard1973]

Having had a think, will I be able to manage it if I get the car up on axle stands or ramps? Don't really want to pay someone else to do it!

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[BlackC55]

The first thing I would be doing is a hot leak off check.

 

[Richard1973]

The first thing I would be doing is a hot leak off check.

The starting issue seems to have resolved itself at the moment. The EGR fault is constantly present. Have tried a can of EGR cleaner, but I suspect mine is blocked beyond a simple fix. I managed to get the 3 bolts out that hold the chamber to the manifold, but it looks like there is a support bracket underneath. I'm guessing I need to unbolt the cooler as well and the bracket for the pipe upto the EGR valve? It started hailing so gave up today. May try tomorrow and get it up on stands.

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[Richard1973]

Have rung 3 different local garages and the Merc specialist I went to for the diagnostics, and not one of them has got back to me with an estimate for doing the job. Did have it up on stands but my enthusiasm for doing it myself has gone! Did check the swirl flap linkage and it is there but disconnected. The linkage moves freely on the manifold and the flaps are open, I guess this is the best default position. Anyone recommend somewhere to do the EGR in the Burton-on-Trent area?

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[Richard1973]

The first thing I would be doing is a hot leak off check.

Having now done the EGR valve, replaced the inlet manifold with a nicely cleaned one, reconnected the swirl flap motor that was not working and replaced the plastic fuel pipes, I'm still having starting issues. Think it must be an injector. I shall take your advice, albeit belatedly!

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[nick mercedes]

Anyone recommend somewhere to do the EGR in the Burton-on-Trent area?

WDM in Birmingham too far away?

 

[Richard1973]

Trying Swadlincote diesels. Bosch service centre and seemed to know what they were talking about. Will report back after they have had a look.

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