Citroen Saxo 1.5d rev counter and running issue.

[JoshDieselSaxo]

Good evening all
This is my first post on here so if I've done anything wrong please do tell me.
I've inherited my grandfathers 2000 Citroen Saxo 1.5d which he bought new. I've got it up and running again having been sat in a field for 5 years, given it a service and sorted a few things out. At some point in the past the supply to the glow plug relay has been a bit iffy so someone has added a separate switch. This in itself isn't a problem. When you turn the ignition on you flick the switch and the glow plugs come on, start the car and everything works as it should, turn it off and the rev counter stops working, the glow plugs stop working and the engine becomes noticeable more noisy. That all makes sense.
This arrangement was all fine until about a week ago when I changed the alternator. Now with the switch on the glow plug warning light comes on and goes off as you'd expect on its own timer and the car starts up no problem at all, so the glow plugs and definitely still working. However, the rev counter doesn't work and the noisy running is now constant regardless of where you put the switch. I've scoured all of the wiring diagrams and bought a replacement TDC sensor to compare resistances. Both the new and existing sensor match and fitting the new sensor didn't fix the problem. I'm no electronic engineer and am rather out of my depth, despite being 22, with anything less than 50 years old.
Any help would be enormously appreciated as I would very much like to keep the car alive.
Cheers
Joshua

[mickthemaverick]

I'd be tempted to replace the iffy glow plug relay and put the wiring back to standard and see how it goes. No idea how the rev counter is involved but I'm sure one of our more Saxo familiar members will be able to offer some advice. Good luck.

[CitroJim]

There's a connection here between the rough running and the rev. counter not working.

It occurs to me the injection pump ECU is not in control of the pump dynamic timing and thus the pump is running on its fail-safe/fallback timing curve; if so then running will be a bit rough. The usual default/fail-safe curve retards the injection timing quite a way from optimum.

Can you help us by describing the nature of the rough running please?

Also, do check the wiring to the pump ECU - both its supplies, connection to the pump and also check the signal from the TDC and needle-lift sensors are present and correct. That a modification to the wiring was made to incorporate a glowplug switch suggests there was and likely still is, a significant electrical problem.

I'm not near my Saxo documentation currently but if need be I may be able unearth it and help investigate.

[JoshDieselSaxo]

Hi there.
Thank you for your response. The rough running isn't necessarily rough like a misfire, but more rough like a tractor. It sounds like a proper old tractor diesel engine, very knocky. I think you're absolutely right with the pump being in failsafe, I just need to figure out why. I can't remember whether I made it clear initially, but it is behaving EXACTLY how it used to when I switched off the glow plugs, the only difference currently being that the glow plugs still work. I think you're probably right with it being control related. I have checked the wiring into the pump and there is nothing obviously out of wack or damaged, although I suppose it's possible I disturbed something while removing the old alternator as this all started once I removed the alternator. I fitted a good second hand unit yesterday so it's now charging fine but no change in the running unfortunately. If you have any Saxo literature and you might be able to find a connection that would explain the issues I would very much appreciate it.
Many thanks
Joshua

[CitroJim]

I'll see what I can do Joshua... Sounding like a tractor and being knocky is a sure sign the timing is not optimum...

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