307 2.0 HDi RHR 136 wont run - no fuel pressure

[Gibbo2286]

Firstly have you got ALL the screws out, my memory's a bit dim but I think there are a couple hidden at the end behind the bell housing cover plate.

Secondly the sump is sealed, as said above, with RTV silicone but there are a couple of lugs on the edge where you can get a pry bar in to gently lever it down.

[RichardW]

The 1.6 HDi sump is also sealed with RTV - however, it has 2 small studs, one at each end, that have a fixed 'washer' in the middle. Once all the bolts are out, you just wind out these studs, and they pull the sump off - easy! It's almost as if they expected sump removal to be a service item Sadly I can't see any such arrangement on the 2.0, so getting a pry bar in there somewhere is going to be necessary....

[tmead]

It was just the sealant holding it on.little more effort and it popped off. Sadly no bits in there !

No bits left in the cam covers either. I have no idea where the rest of that pump drive went.

It's time to put it back together now. I give up with trying to find the bits. They have lived in there for a good while, and will have to stay.

I can't find the injector seat cutter in the garage, and one of the washers came out with aluminium bits on it. It's been about 4 years since I used it and I now have no idea. The local motor factors quoted me a hundred quid today for a kit, and I can't stretch that far just to prompt finding the one I already own! It's going back in with a new washer and I'll see how it seals. Provided the weather isn't too crap it's planned to be finished this weekend. Maybe I'll spring for another Ebay special and sort the injector after that.

[Gibbo2286]

I wonder if that's been fixed before and your 'missing bits' were never there, maybe someone chanced his arm and put it back with an already damaged part.

[tmead]

Could be !

It's all back together. Quite tired yesterday evening by the time I finished, so I'll review this morning, pop some oil in and crank it up. Fingers crossed.

[tmead]

Well that's a shame.

It won't fire up. It coughs as if only on one cylinder but doesn't catch. I assumed that electronic injectors would be self bleeding ? All the dire warnings about not cracking a pipe nut like injectors of old and all that. I've pumped the prime bulb until it firms up. Not sure if there's a special method for priming the fuel pump.

I now have fuel pressure anyway, so that's a good start.

Not quite sure where to go next ?

[tmead]

Just opened the return line and pumped a couple of jam jars of fuel through with the primer bulb. There was quite a bit of air passed through too. I kept going until no more bubbles came out.

Still no different. Coughing as if it's firing on one.

[tmead]

Well it now has started ! running very lumpy, but I was kind of prepared for the injector I had to take the top off to extract to be dead.

Sadly I have a leaking return pipe, and will have to deal with that now, even before a first test drive, as there's rather too much diesel floating about on top of the engine ! Stupidly I saw some little metal clips and popped them out to release the return pipes. They are a sod to get back in, and it looks like I missed slightly with one. They are going to be a right pain to get to, probably need to strip the inlet manifold back off I guess. Its a weekend, and I've now had enough, so I'm stopping !
Should have just pulled the pipes off - seems they come quite easily

[tmead]

All the bits are available on ebay for a few quid, but only for delivery tomorrow ! Ford garage in town could get the equivalent parts, but the pipe set is a hundred quid, and the clips are 7 each ! Looks like I'll have to wait another day.

[EDC5]

Glad to hear that it has started.

Hope you can get it going properly.

[tmead]

First drive for a couple of weeks ! Yay !

Top tip - those little plastic connectors for the leakoff pipes slide in much easier with a small smear of grease. The lubrication properties of diesel are not good enough !

One injector seat recut as some material came out attached to the copper washer. They all appear to be sealed up. No chuffing or leaking apparent at the moment.

It ran like a right pig when it first started up, really lumpy and loads of white smoke. I was convinced that I'd knackered on or more of the injectors. A run up and down the road seems to have straightened them out though, and it's running much better. PP shows injector 4 with a correction of 110% while the other three are all at around 95%. Not sure if that's important ? I'll see how it pans out.

All errors cleared, just waiting to see what pops up. The EGR will probably still throw an error as I have no idea how to teach it in after replaceemnt. It is blanked and doesn't cause limp or anything. Turbo feedback seems to be changing now at least. I forgot to look for the value at key on, engine off. I think that should be 11% ?

Fingers crossed now !

[tmead]

Turbo repeat now sits at 12% with key on, engine off, so thats much better. Economy is OK, starting is fine,power is OK, but perhaps still 'lumpy' at full throttle with the turbo singing around 3K.
More live data may help show up what is going on, but there are other more pressing calls on my time right now.

Thanks for all your help and support !

[EDC5]

Turbo repeat now sits at 12% with key on, engine off, so thats much better. Economy is OK, starting is fine,power is OK, but perhaps still 'lumpy' at full throttle with the turbo singing around 3K.
More live data may help show up what is going on, but there are other more pressing calls on my time right now.

Thanks for all your help and support !

Glad you've got it sorted to the point that it's not taking up all of your time

[tmead]

spoke too soon - see new thread on injectors. <sad face>