307 2.0 HDi RHR 136 wont run - no fuel pressure

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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by tmead »

Darn, posts crossed.

Engine change is more than that I suspect though. Not sure which is rather do.

Or maybe this is the death knell.....
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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by tmead »

Is there a gasket between the two metal parts of the head around the camshaft ? I can only see a gasket set for the inlet manifold. Once the upper metal part is lifted away the camshaft is exposed - should that be refitted with magic goop <frown> ?

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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by xantia_v6 »

It occurs to me that the broken camshaft could be due to a manufacturing defect causing a stress point, or it could be a fault in the pump or pressure releif valve that caused it to intermittently jam, or hydraulic lock. I would suggest changing the pump (even for a second hand one) as a precaution.
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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by RichardW »

Tim, yes the upper camshaft cover needs RTV silicone on it to seal it. I will e-mail you the procedure later (it will be for a C4, but I would guess functionally the same).
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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by tmead »

I have a s/h pump here now. Its not proven, but I was also worried about the possibility of an intermittent fault with the pump stressing the camshaft yoke.

Any manufacturing defect has done pretty damn well to last 190K. I shouldn't complain too much, its had a clutch, a turbo vac valve, one EGR and will shortly be getting a turbo repeat sensor now I can see and reach it. Probably needs its first DPF change before long too. Not too shoddy for the 100K that I've put on it.

Now I'm just hoping that there's no other evidence of damage one I get the rocker cover off.

Details of the sealing procedure would be gratefully received.
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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by tmead »

Ive now taken off the pipe leading to the turbo inlet. I'm sure it should be fixed to the turbo, but once i took the battery tray and hp pump off it was only held in place by one screw up the top. Looking down around the back of the engine with the camera i can see a small mounting hole next to the turbo inlet, but it doesn't appear to be threaded. Is there a funky push in type fitting that is supposed to be in there ? Or maybe it is threaded and I just don't see it yet ?

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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by tmead »

Looks like my decision to repair was a poor one. Should have listened to the advice provided earlier. Three injectors are out, but the fourth doesn't want to budge. Theres no evidence of blowby, but I guess over the last decade and 190k it's corroded a bit and seized in there.
There are loads of kits for 1.6 and early 2.0, but I can't identify a simple or basic kit for a 16v 2.0 RHR engine. Anybody around the cambridge area got anything that will help ? I've even looked for a removal service, but can't find anyone more local than about 40 miles away. Might have to try them on Monday if I have no luck tomorrow.

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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by tmead »

Whilst soaking the injector I've tidied up further.

Looks like the yoke on the end of the camshaft broke quite a long time ago. It's been driving on just one side of the cross piece for long enough to mark it heavily.
Only reason it stopped now is that the yoke has cracked across the area that is shrunk onto the camshaft so it simply lost drive.

I'm worried that I can't find any of the broken off pieces of the yoke. I know I haven't got the top off the head yet, but I expected to be able to fish some pieces out with a magnet. I guess the pocket under the drive area is open right down through the head so the pieces may have dropped down to the sump.
Marking on the cross piece
Marking on the cross piece
15243929669521770093792.jpg
Theres a scary amount of this yoke missing
Theres a scary amount of this yoke missing
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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by tmead »

OK, so the last injector is out ! One 30 quid kit from Amazon as a last ditch effort and it pulled straight out. Everything else looks straightforward (!) now.

That's at least what I thought, until i popped the special socket on the top of the last stud and the little torx type end on the top just sheared right off. I could have cried ! its now come loose by tapping round on the tapered flange portion with a centre punch to break it free and then mole grips to turn it out. Even better, a pair were readily available on ebay for 4 quid, delivered before the weekend ! OK, maybe not so bad.

I've popped the cam cover off now, and haven't found any more pieces of that yoke, so I guess they must all have flushed down to the sump.

Shame that even though I can see the turbo repeat sensor behind the engine, its so tight to the body that I cant even get the simplest of screwdrivers in there to undo the three cross head screws. Looks like I'll have to slacken or remove the top engine mount to allow the engine to swing slightly forward and down to give a touch more space. With that and dropping the sump to try to find the broken pieces of the drive yoke I've got a few things to do before starting to put it all back together. I can't see a sump gasket on servicebox, so guess that's also sealed on with goop.
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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by myglaren »

Could you get a cranked screwdriver in?
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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by tmead »

I've got one of those somewhere. Good idea,, I'll give it a go.
Crazy plan to put cross head screws in there. Three little hex head bolts would have been fine, and could have been out by now !
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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by xantia_v6 »

Best tool for that kind of operation is often a 6mm hex shank bit and a 6mm ratchet ring spanner.
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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by Gibbo2286 »

Are you sure those screws are cross heads and no torx?
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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by tmead »

Yep definitely cross. Phillips #1.
I popped the engine mount off and lowered it forward a bit to get some more access and could get in with a sweet little rolson ratchet. It's tiny, and very much the kind of set your auntie would give you! About 2 inches long and made of plastic. Probably won't last long.

The sensor that came off still is sprung and moves pretty well. Not quite sure why it was reporting a constant value. Have to wait and see what happens when it's all back together and powered up.

Sump screws are all out, but it seems well stuck on. Not sure what kind of sealant is on there, but it doesn't want to give. I really want to find those broken bits, so it's coming off.
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Re: 307 2.0 HDi RHR 136 wont run - no fuel pressure

Post by EDC5 »

This is a very concerning development re. the broken camshaft yoke. I'm interested to find out where the other pieces of it ended up and how they didn't cause instant destruction of the engine after thrashing around in the rocker cover for a bit!

I'm assuming the sump is sealed with RTV silicone so might need some persuasion to come off.
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