DW10FC Injector replacement (Proace Verso 2.0 180ps, but same as Traveller)

[Mr Fusion]

Hi Guys

First post here!

I have a 2018 Toyota Proace Verso, but thought I would ask here as should be identical engine-wise to a Peugeot Traveller.

It's fairly high mileage for the year at 140,000 miles, but runs well and has all the extras such as leather etc.

MPG is not what I was expecting (around 23 to 27 mpg), so got myself a diagbox set up and did some testing on the injector correction values (wrote some software to load up the xml files diagbox produces to analyse afterwards). As they are original injectors, I hunted down a low mileage replacement set on ebay which should arrive in the next few days.

Have managed to get the old ones out, but had to do a slight workaround as can't figure out how to completely remove the plastic cover that sits between the other pipes and the injector hardware below. Undid most of the bolts for it, enough to get at to remove them. They were all fairly mucky and all came out with the copper seals apart from cyl 1.

Now the problem will now be cleaning the ports to get the new ones in (due to the poor access) - I have bought the cleaning tools to do the job from Amazon - but is there a trick to getting the cover off on the right hand side of the engine near the air intake?

Cheers

Ben

[Mr Fusion]

Its the cover in this area circled

[Mr Fusion]

p.s have already replaced air and fuel filters and the fuel pressure sensor

[Mr Fusion]

Managed to do it without removing that cover - however put it all back together and then noticed one of the new copper seals on the floor!

Worked out which one it was by laying a flat straight piece of metal across the top of the injectors to see which was sitting lower by approx 2mm (it's number 1, nearest the gearbox).

Will have to get in there again and fit the washer - will probably have to order a new bolt for that cylinder as they are torque to yield, but will probably be ok for a short while.

[Mr Fusion]

Got the seal installed, coded the new injectors and did the fuel system priming procedure in diagbox (as well as priming via the low pressure pump about 10 times).

Engine will try and run but sounds like its running on 2 cylinders - then it will stall. Pulled the high pressure sensor in the rail while cranking and its squirting out diesel, could be an air lock further up towards the injectors.

Tried some easy start spray but makes no difference. Have now flat battery so charging up to try again tomorrow - any tips? (doesn't have a manual priming pump by the fuel filter).

[Mr Fusion]

p.s did the actuator tests for injectors, low press fuel pump and air mixer and all passed (and can hear them working)

[Muir]

Hi,

Don't know if you managed to get the car running, but you're most likely spot on about air pockets in the fuel line.
When changing injectors it's important to both prime pump like you did, but also disconnect the plugs from the solenoids and turn the starter over for some 6+ seconds.
This will prime the injector lines without risk of damaging them due to no lubrication (diesel fuel) - they wear *fast* with no diesel in the system

[Mr Fusion]

I have pulled and reinstalled the injectors as #1 wasn't sealing properly due to me missing some crud on the seat. Not managed to keep it running yet so will try what you suggested tomorrow after battery has charged again.

I will add that I have updated the ECU and BSI software with paid Diagbox to make sure the new injector codes (2022) are compatible with the ECU.

If this doesn't work I will install the old injectors again to rule out issues with the new ones (blocked / faulty)

[Muir]

Good thing you spotted that, let's hope it was the only issue!
Can't imagine recoding the injector offset values could have any but good results, it should start and run even if you didn't

[Mr Fusion]

So just so I am clear - you are suggesting to disconnect the injector electrical plugs and turn the starter over?

[Muir]

Yes exactly.
If theres insufficient/no diesel in the injector lines and they are electrically connected, they will actuate with metal-to-metal contact between the injector needle and the nozzle tip.
Disconnect the plug and it won't actuate, but the lines will still get primed and diesel just get bypassed through the return line.

[Mr Fusion]

Gotcha - makes sense as then high pressure pump will be running from engine cranking and hopefully push any air out of the return line

[LedZep]

[Mr Fusion]

Thanks - found those exact videos as well - hopefully this will get it started.

[Mr Fusion]

Still not working.

Disconnected the high pressure regulator connector and the injector plugs and did the crank procedure (also tried undoing the high pressure fuel line unions to get air out there - diesel came out of each, although not a lot).

Pressure reports as 1291 bar when cranking with the regulator disconnected.

It tries to start but then always dies at around 800rpm - every single time.