1.6HDi not starting...

[Auldalliance]

Question- what is the black plastic box? Circled in yellow in this screen grab from a video.
And does it need to come out?

[Auldalliance]

I did manage to get a bit more working space, and tried bridging the solenoid with a screwdriver, and the ignition key in the run position. I got a bit of sparking but fairly weak. What would that indicate?

[mickthemaverick]

It sounds like your starter motor's brushes may have failed causing a partial short across the terminals.

[Steve Walsh]

IThe black plastic box looks like the fuel filter, Some of the 1.6 diesels had them like that, there will be quick release fittings and then it slides oupwards from its locating slot.
The last starter I had off a 1.6 was done from underneath and the top bolt was done using a very long extension on a allen key socket. It is a struggle but do able

[RichardW]

Here's my take on it when I tried to do it on my 307: https://www.frenchcarforum.co.uk/forum/ ... &start=307

Never did get the top bolt out - not that much longer after that I found both sills were rusty and it got scrapped!

[mickthemaverick]

That link took me to a thread about Mandrake's boiler?

[MattBLancs]

Here's my take on it when I tried to do it on my 307: https://www.frenchcarforum.co.uk/forum/ ... &start=307

Never did get the top bolt out - not that much longer after that I found both sills were rusty and it got scrapped!

Unbolt the vac reservoir (a wholly OTT 16mm bolt )

Ha ha! I'd completely forgotten about that massive bolt holding a (weighs virtually nothing!) vacuum reservoir!

I'll be getting flashbacks at this rate

[Auldalliance]

Yes looks like the plastic box is a fuel filter.
I'm used to boat engines, this all looks very odd to me

Anyway I made some solid progress this afternoon. Finally got the battery tray right out (had to peel back the wheel arch liner and do the awkward bolt from that side. It won't be going back in!
Got the fuel filter jiggled out of the way. Didn't disconnect anything.
And I've now got two of the long allen head bolts completely out, the the third one about half way. Stupidly I pulled the socket extension off to change to a shorter one as I'd run out of space, and now I can't get it back in again. Grrr.

Anyway run out of patience and battery for my torch. Will resume tomorrow...

[MattBLancs]

Yes, it's a good job to break off and come back with fresh enthusiasm!

Keep up the good work

[Auldalliance]

Success!
After a lot of swearing and skinned knuckles, I finally wrestled the starter out. It's like keyhole surgery.
I have a borescope on order now, which should make replacement a bit easier.

Anyway, the starter is behaving exactly as I suspected it might: it will run for a bit if I bang it with a hammer, but otherwise acts pretty much dead, with a few sparks and clicks.

Time to order a replacement.

Thanks to everybody who offered help and encouragement

[Steve Walsh]

Well done. When you install the replacement, There is a locating dowel in one of the bolt holes, Fit it into the starter not the bell housing before tring to get it in.

[Auldalliance]

So, after a bit of a delay, I got the new starter installed today.
And... success! Engine fired straight up.
What a b*stard of a job

Still need to secure the battery properly.
Also, I discovered a length of clear-ish plastic tubing which wasn't connected at either end, and had burn damage in the middle, possibly from touching the turbo. Bit of a mystery. Looks like windscreen washer hose or similar. I'll stick a photo up later.

[Steve Walsh]

So, after a bit of a delay, I got the new starter installed today.
And... success! Engine fired straight up.
What a b*stard of a job

Still need to secure the battery properly.
Also, I discovered a length of clear-ish plastic tubing which wasn't connected at either end, and had burn damage in the middle, possibly from touching the turbo. Bit of a mystery. Looks like windscreen washer hose or similar. I'll stick a photo up later.

Probably drain hose from fuel filter..