2003 Relay 2.0 HDI cutting out help please.

[robdav99]

HI all, I'm Rob and I've been doing a lot of googling for help since I got this van and this site kept popping up so thought I would join.

I've recently acquired a 2003 Relay with the 2.0L HDI engine (RHY I think?), It was a friends but he gave up on it and was going to scrap it so I thought I would try and save it.

The problem it has (or the main one anyway, there are few minor ones :-p)

While driving the van if the revs rise above 2100rpm for too long it will cut out, completely dead. It will restart straight away usually and drivers quite nicely until you reach the magic 2100rpm.

In some cases the van will go into limp mode and MIL lamp will illuminate, where the revs will not go above 2100 anyway but it will not cut out when in limp mode.

The van has had fault codes read by several garages and types of equipment and everytime no fault codes have been found. Even when engine running and MIL lamp lit.

I have taken the injectors out and had them looked at by a specialist and he said they where worn beyond refurb.

So I bought some of ebay, which where from a vehicle that ran well (apparently) and this has made no difference.

Ive done a diy leak back test on the new(to me) injectors and the readings after 15mins of idling are:
cylinder 1 = 140ml
cylinder 2 = 120ml
cylinder 3 = 120ml
cylinder 4 = 180ml

injector 4 looks abit more worn than the others but I think within tolerances? does anyone know what should be standard leak back on these engines?

Ive replaced the fuel filter and checked that the intank pump runs correctly.

What else should I be looking at with this?
Are there any sensors that could cause this sort of issue?

Any help/advice greatly appreciated.
Thanks

[myglaren]

Welcome to the forum Rob.

I would check the in-tank filter and lift pump (if there is a lift pump - depends on system).
Filter can clog up with a sort of gel.

[RichardW]

Unlikely there are no fault codes if read with a Lexia. My guess would be that the fuel pressure reg on the end of the pump is playing up - if the ECU has to wind this right out, and the rail pressure is still not what it is expecting, then it assumes there is a high pressure fuel leak and it stops the engine - just as if you had switched it off.

[BX]

Assuming Bosch injection system, the problem is the fuel pressure regulator on the high pressure pump. The engine will cut out as you describe but will restart with no issues after being left a few minutes. The problem is a tiny filter on the end of the regulator. This filter cannot be successfully cleaned. You have two options. The best is to fit a new regulator. The other is to remove the filter. This topic is already well covered on this forum.
When the fuel rail pressure reaches the desired pressure the needle on the regulator is lifted allowing fuel to return to the tank and thus controlling the pressure. When this filter blocks the pressure cannot be controlled at higher rpm. As a safety measure the ECU stops the engine. The filter is purely to protect the needle and seat in the regulator. The fuel which passes through the regulator is returned to the tank. Another symptom of this filter being blocked is a tendency for the engine to run on after the ignition is switched off.

[robdav99]

A quick update.

I've replaced the regulator with a brand new Bosch one and the problem is still there. Is there supposed to be an o ring on the indentation that is on the body of it near the bolt holes? Because neither the old or new one had one but it looks like an o ring is meant to be there?

I bought and eBay lexia kit and it won't talk to the car ECU.
Connects to the laptop and software fine but just comes back with no dialouge with ECU every time.

Any ideas?
Cheers

[BX]

Cannot help with the lexia as I never used one. Any regulator i removed had only a metal gasket. There is usually a tiny o ring at the filter end often green in colour.
I forgot to mention checking the regulator filter using a good magnifying glass. A clogged filter will show up as having whiskers when magnified. I havent come across any other fault on these engines which cause them to stop in the fashion you describe and then allow them to restart. These faults do not usually bring on an eobd fault on most makes. The logic is that the eobd standard only relates to faults likely to affect emissions. When the engine is stopped there are no emissions A standard eobd code reader would therefore not usually detect a fault. A code reader with manufacturer specific software is needed. Obviously the lexia / diagbox system is best as these sre clones of the dealers system. However there are plenty of other options which can read manufacturer specific faults for one or several makers. They are from suppliers such as Bosch, Delphi, Snap on, Sealey, Foxcon, Autel, Launch, Autoboss and others. I use Delphi which i find good on european cars but poor on Japanese and other Asian makes especially models launched before 2005.
If the van is in limp mode or has the mil lamp lit there would normally be fault codes there to be read. I have no idea why they didnt show up to the diagnostics.

[elma]

There have been issues with the cables on Lexia clones. I'm not sure exactly what as I've never used one but there's answers around and quite a few of the gang are really knowledgeable about Lexia.

[Bick]

Ill send you a PM

[Peter.N.]

If this is a 2.0. 8 valve engine I have never heard of injector failure, I have two, one has done 242k miles and the other 200k and as far as I know the injectors are original. If you do have a problem you can buy them very cheaply off ebay, I have seen a set for about £25, evidence theat they don't often go wrong.

I would suspect the pressure regulator on the back of the HP fuel pump, is that the one you have changed? I have had several problems caused by that. I suppose the fuel filter has been changed?

Peter