I have a no start problem and could do with some pointers if anybody has any diesel expertise.
For context:
I had a problem with an oil leak around the front of the engine and the DPF clogging level was causing an EML. Realising that to find the leak properly I would have to clean the front of the engine I also decided to try removing the DPF and try a DIY cleaning. I also needed to fit two new wishbones as well. And a new condenser as the old one was falling to bits. So, I did the following:
Removed wheels, inner wings.
Removed bumper, headlights, crash bars, condenser, radiator and intercooler.
Removed battery and tray, turbo and DPF.
Removed oil cooler.
Removed wishbones.
I then set about cleaning the front of the engine and underneath as well. The DPF I cleaned using Wynns off-car DPF cleaner overnight. I am unsure how successful this will be but have my doubts. Might need a new one.
The turbo was toast - axial movement of 1-2mm, shaft blued and oil in both sides. New turbo purchased.
Some leakage was found on the high pressure pump pressure regulator so I removed that, cleaned both mating faces under the pump and refitted.
After all was shiny and clean I proceeded to rebuild the car. New oil and filter and new coolant all went in. I was extremely chuffed when the engine started at the first turn of the key. I left it running while I topped up oil and coolant. No leaks were evident anywhere so time for a test drive.
I connected up the laptop, ran MES and all looked good. At this point the exhaust was blowing a lot of crap from the DPF cleaning so I thought it might need a forced regen. Off we go and about a mile down the road it threw an EML for DPF clogging so I decided to turn round at the next junction and come back to try a forced regen.
As that thought went through my mind, the engine cut out. There was no hesitation, no unusual sounds, nothing. It was like it was a petrol engine and the ignition was turned off. I managed to use the last momentum to get it off the road and tried to restart. Turned over nicely, but no start. A quick look under the bonnet revealed nothing obvious so I walked home and arranged for the car to be recovered.
Back at base, air cleaner off and nothing obvious showed itself. I again ran MES and began checking parameters. First thing that jumped out was zero pressure in the common rail when cranking. Coupled with the instant cutout my first thought was timing chain. To confirm this I removed the timing port on the rear camshaft and watched while my wife turned the starter. Thankfully, the cam was turning so chain and cam gears all ok.
I then checked diesel flow out of the fuel filter and that was fine. I then decided to crack the number one cylinder high pressure pipe and try cranking. However, as soon as I turned the ignition on, fuel started pouring out of the line, presumably at lift pump pressure. Should this happen? I would have though there would be no pressurised fuel in the rail until the HP pump starts turning.
I checked that engine RPM is being shown on MES during cranking so I am pretty sure the crank sensor is working. The pressure regulator signal rises from 10% to 60% when cranking so presumably that is ok - or is it? Maybe I did something to it but I have no idea how to test this.
I am now at a complete loss what to do next. Any suggestions or steps I should try would be very welcomed.
For context:
I had a problem with an oil leak around the front of the engine and the DPF clogging level was causing an EML. Realising that to find the leak properly I would have to clean the front of the engine I also decided to try removing the DPF and try a DIY cleaning. I also needed to fit two new wishbones as well. And a new condenser as the old one was falling to bits. So, I did the following:
Removed wheels, inner wings.
Removed bumper, headlights, crash bars, condenser, radiator and intercooler.
Removed battery and tray, turbo and DPF.
Removed oil cooler.
Removed wishbones.
I then set about cleaning the front of the engine and underneath as well. The DPF I cleaned using Wynns off-car DPF cleaner overnight. I am unsure how successful this will be but have my doubts. Might need a new one.
The turbo was toast - axial movement of 1-2mm, shaft blued and oil in both sides. New turbo purchased.
Some leakage was found on the high pressure pump pressure regulator so I removed that, cleaned both mating faces under the pump and refitted.
After all was shiny and clean I proceeded to rebuild the car. New oil and filter and new coolant all went in. I was extremely chuffed when the engine started at the first turn of the key. I left it running while I topped up oil and coolant. No leaks were evident anywhere so time for a test drive.
I connected up the laptop, ran MES and all looked good. At this point the exhaust was blowing a lot of crap from the DPF cleaning so I thought it might need a forced regen. Off we go and about a mile down the road it threw an EML for DPF clogging so I decided to turn round at the next junction and come back to try a forced regen.
As that thought went through my mind, the engine cut out. There was no hesitation, no unusual sounds, nothing. It was like it was a petrol engine and the ignition was turned off. I managed to use the last momentum to get it off the road and tried to restart. Turned over nicely, but no start. A quick look under the bonnet revealed nothing obvious so I walked home and arranged for the car to be recovered.
Back at base, air cleaner off and nothing obvious showed itself. I again ran MES and began checking parameters. First thing that jumped out was zero pressure in the common rail when cranking. Coupled with the instant cutout my first thought was timing chain. To confirm this I removed the timing port on the rear camshaft and watched while my wife turned the starter. Thankfully, the cam was turning so chain and cam gears all ok.
I then checked diesel flow out of the fuel filter and that was fine. I then decided to crack the number one cylinder high pressure pipe and try cranking. However, as soon as I turned the ignition on, fuel started pouring out of the line, presumably at lift pump pressure. Should this happen? I would have though there would be no pressurised fuel in the rail until the HP pump starts turning.
I checked that engine RPM is being shown on MES during cranking so I am pretty sure the crank sensor is working. The pressure regulator signal rises from 10% to 60% when cranking so presumably that is ok - or is it? Maybe I did something to it but I have no idea how to test this.
I am now at a complete loss what to do next. Any suggestions or steps I should try would be very welcomed.
