Berlingo 1.9d plllleeease help

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wilba2880
Posts: 12
Joined: 11 Dec 2015, 21:46
Location: hampshire
My Cars: berlingo 1.9d

Berlingo 1.9d plllleeease help

Post by wilba2880 »

hi, i have bought a 2002 berlingo 1.9d van to restore and maybe come up with a few ideas with but it has a very nasty problem.
The van smokes and runs pretty rough, so after investigating i unplugged the advance solenoid and discovered it ran brilliant but sounded rather knockey, i replaced the solenoid and it still smokes and runs rough i then found that the flywheel lugs had snapped off so i replaced the flywheel thinking this would help.
it never.
i then checked the timing and its perfect.
so i really need help as to what to check now.
please please help me.

thanks
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chinkostu
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My Cars: N Xantia 1.9TD SX
03 Fiesta 1.4 Zetec
x 30

Re: Berlingo 1.9d plllleeease help

Post by chinkostu »

This is the dw8 engine with the silly weird pot on top of the pump arm isnt it? Mine always sounded like a bag of spanners too.

Try unplugging the EGR multiplug and see if it helps, it will however bring the engine light on. After that make sure the load lever pot actually works, mine used to bog down and smoke randomly until i replaced the pot
Stu

Cars
1995 Xantia 1.9TD SX in (faded) Red
2003 Fiesta 1.4 Zetec in GREEEEEEEN
2001 206 1.9 LX
2001 Saxo VTR
1999 Saxo 1.1 East coast
1999 Punto :oops:
1996 306 1.8 XN Auto :?
1996 Fiesta 1.3 #-o
wilba2880
Posts: 12
Joined: 11 Dec 2015, 21:46
Location: hampshire
My Cars: berlingo 1.9d

Re: Berlingo 1.9d plllleeease help

Post by wilba2880 »

Thanks for the quick reply. I know this sounds daft but what is the load pot. Lol. Also is the van safe to run with the advance solenoid unplugged or not. Thanks again
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chinkostu
Posts: 1180
Joined: 24 Sep 2014, 09:41
Location: cheshire
My Cars: N Xantia 1.9TD SX
03 Fiesta 1.4 Zetec
x 30

Re: Berlingo 1.9d plllleeease help

Post by chinkostu »

If you look at the fuel pump its the little box that sit on top of the "throttle arm" (yes i know diesels dont have them!) With three wires coming out of it.
The ecu uses this, the crank sensor and the needle lift on injector 4 to slightly alter timing based on temperature and load. Which reminds me, if you unplug thr crank sensor (on flywheel side, 3 pin multiplug) or the needle lift (tiny one plug jobbie on injector 4/1) does it stay rattly? As it'd mean one of these has had it usually.

Its strange that unplugging the advance would do that though.


If its smoking it could be overfuelling which isn't great, personally if its only a bit knocky when unplugged it should be the better of two evils.
Stu

Cars
1995 Xantia 1.9TD SX in (faded) Red
2003 Fiesta 1.4 Zetec in GREEEEEEEN
2001 206 1.9 LX
2001 Saxo VTR
1999 Saxo 1.1 East coast
1999 Punto :oops:
1996 306 1.8 XN Auto :?
1996 Fiesta 1.3 #-o
wilba2880
Posts: 12
Joined: 11 Dec 2015, 21:46
Location: hampshire
My Cars: berlingo 1.9d

Re: Berlingo 1.9d plllleeease help

Post by wilba2880 »

So is it safe to drive without the solenoid plugged in it passed the emissions mot. Just don't want to cause more damage to it.
wilba2880
Posts: 12
Joined: 11 Dec 2015, 21:46
Location: hampshire
My Cars: berlingo 1.9d

Re: Berlingo 1.9d plllleeease help

Post by wilba2880 »

If I drive it without the solenoid plugged in will it damage the engine
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chinkostu
Posts: 1180
Joined: 24 Sep 2014, 09:41
Location: cheshire
My Cars: N Xantia 1.9TD SX
03 Fiesta 1.4 Zetec
x 30

Re: Berlingo 1.9d plllleeease help

Post by chinkostu »

With it unplugged it will default to however far the pumps advanced physically. Can't see it doing anything but i cant condone it!
Stu

Cars
1995 Xantia 1.9TD SX in (faded) Red
2003 Fiesta 1.4 Zetec in GREEEEEEEN
2001 206 1.9 LX
2001 Saxo VTR
1999 Saxo 1.1 East coast
1999 Punto :oops:
1996 306 1.8 XN Auto :?
1996 Fiesta 1.3 #-o
wilba2880
Posts: 12
Joined: 11 Dec 2015, 21:46
Location: hampshire
My Cars: berlingo 1.9d

Re: Berlingo 1.9d plllleeease help

Post by wilba2880 »

Me again. I have changed the solenoid the black thing you mentioned and the last injector and it still runs awful when the solenoid is plugged in. Any ideas.
wilba2880
Posts: 12
Joined: 11 Dec 2015, 21:46
Location: hampshire
My Cars: berlingo 1.9d

Re: Berlingo 1.9d plllleeease help

Post by wilba2880 »

Still no joy with this. Anyone about to give me some advice please
wilba2880
Posts: 12
Joined: 11 Dec 2015, 21:46
Location: hampshire
My Cars: berlingo 1.9d

Re: Berlingo 1.9d plllleeease help

Post by wilba2880 »

When the advance solenoid is plugged in it runs awful the timings out and it smokes like a chimney. Once I unplug the solenoid its runs smooth just quite knockey. I've unplugged the needle kid which made no difference and I unplugged the load thing and it also made no difference. I'm totally baffled
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chinkostu
Posts: 1180
Joined: 24 Sep 2014, 09:41
Location: cheshire
My Cars: N Xantia 1.9TD SX
03 Fiesta 1.4 Zetec
x 30

Re: Berlingo 1.9d plllleeease help

Post by chinkostu »

When you replaced the flywheel did it have the right amount of lugs for the crank sensor? And is the rev counter reading right?

Its a puzzling one as usually unplugging the solenoid leads it to sound like a tank!
Stu

Cars
1995 Xantia 1.9TD SX in (faded) Red
2003 Fiesta 1.4 Zetec in GREEEEEEEN
2001 206 1.9 LX
2001 Saxo VTR
1999 Saxo 1.1 East coast
1999 Punto :oops:
1996 306 1.8 XN Auto :?
1996 Fiesta 1.3 #-o
wilba2880
Posts: 12
Joined: 11 Dec 2015, 21:46
Location: hampshire
My Cars: berlingo 1.9d

Re: Berlingo 1.9d plllleeease help

Post by wilba2880 »

Yes it had 2 lugs on it and the revs are reading perfect. When you unplug the solenoid it does sound like a tank but ticks over in perfect time. Once the solenoid is plugged back in the timing goes out and it smokes. I have replaced the solenoid though it's a new one
wilba2880
Posts: 12
Joined: 11 Dec 2015, 21:46
Location: hampshire
My Cars: berlingo 1.9d

Re: Berlingo 1.9d plllleeease help

Post by wilba2880 »

Hi I thought I'd bump this up to see if anyone else could maybe help
wilba2880
Posts: 12
Joined: 11 Dec 2015, 21:46
Location: hampshire
My Cars: berlingo 1.9d

Re: Berlingo 1.9d plllleeease help

Post by wilba2880 »

So an update if anyone's reading. I've noticed that when the advance solenoid is plugged in air bubbles appear in the clear fuel line from the fuel filter housing. Would this have anything to do with the van running rough.
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chinkostu
Posts: 1180
Joined: 24 Sep 2014, 09:41
Location: cheshire
My Cars: N Xantia 1.9TD SX
03 Fiesta 1.4 Zetec
x 30

Re: Berlingo 1.9d plllleeease help

Post by chinkostu »

wilba2880 wrote:So an update if anyone's reading. I've noticed that when the advance solenoid is plugged in air bubbles appear in the clear fuel line from the fuel filter housing. Would this have anything to do with the van running rough.
Air in the fuel causes havoc actually! Jim might have an idea of how its getting there, maybe the seal around the solenoid is perished?
Stu

Cars
1995 Xantia 1.9TD SX in (faded) Red
2003 Fiesta 1.4 Zetec in GREEEEEEEN
2001 206 1.9 LX
2001 Saxo VTR
1999 Saxo 1.1 East coast
1999 Punto :oops:
1996 306 1.8 XN Auto :?
1996 Fiesta 1.3 #-o
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