Hi,

I have a 2007 Citroen Berlingo 1.6 HDi with the DV6TED4 engine.

After changing the injector seals and fuel priming pump (and associated hoses) the van will not start.
The engine turns over fine and the starter motor is brand new, after the old one failed after trying to start the engine.

Checked so far:
Fuel system primed for several hours, even using an electric pump. Fuel filter checked, was only replaced 2 months ago. Fuel appears to be reaching all parts of the fuel system, including the injectors.
One injector was tested whilst removed from the engine, and diesel was spraying out of it while cranking.
Glow plugs tested, over 50% of the end of the plug is glowing red when removed from the engine. Measured resistance of each glow plug is 1.2 ohms. We have powered the glow plugs directly from the battery to rule out the glow plug relay.

I have run out of options and would appreciate any advice, thank you in advance!

I don't know if a BSI reset will help.There is a thread about it.Where are Rustcrat,Addo & lighty when you need them?:whistle: PS have you checked all relevant fuses?

(22-03-2014, 08:38 PM)ron Wrote:  I don't know if a BSI reset will help.There is a thread about it.Where are Rustcrat,Addo & lighty when you need them?:whistle: PS have you checked all relevant fuses?

Thanks for the reply. I attempted the BSI reset procedure twice, and I cannot confirm if it worked or not. Fault codes are still present, so either the reset procedure did not work or the BSI reset does not clear the fault codes. I am aware my keyfob battery is running low, sometimes I have to leave it for a few seconds after repeated use before it will work again, although I presume holding the lock button down is to store the code of the keyfob into the ecu. I did hold it down for a good 12-15 seconds both times.

All fuses were checked because we suspected an issue with the glow plugs.

Fault Codes:
P1113 Intake Air Temperature (Sensor was unplugged)
P0193 Fuel Pressure Sensor "A" Circuit High (Appeared after using an electric pump to bleed the system. Manual pump was ineffective due to being new and full of air.)
P0104 Mass Air Flow (Sensor was unplugged)

Prior to starting work:
P0402 Exhaust Gas Recirculation "A" Flow Excessive Detected
P3008 Unknown (Turbo/EGR from what I remember)

The turbo was also replaced along with oil pickup, feed pipes etc hence the previous fault codes.

Our first thought was an air lock in the fuel system but we have spent several hours bleeding the system and removing one injector had fuel spraying out at regular intervals.

This is a longshot but it's worth a try. If you have a different key then I'd suggest trying it as it's possible the immobiliser chip in the key may have failed. I had this problem a few years back with an Escort van, it had three keys when I bought it and refused to start with one of them but was fine with the other two.

Sent from my GT-P3110 using Tapatalk

(22-03-2014, 09:20 PM)SolentCarAudio Wrote:  

(22-03-2014, 08:38 PM)ron Wrote:  I don't know if a BSI reset will help.There is a thread about it.Where are Rustcrat,Addo & lighty when you need them?:whistle: PS have you checked all relevant fuses?

Thanks for the reply.  I attempted the BSI reset procedure twice, and I cannot confirm if it worked or not.  Fault codes are still present, so either the reset procedure did not work or the BSI reset does not clear the fault codes.  I am aware my keyfob battery is running low, sometimes I have to leave it for a few seconds after repeated use before it will work again, although I presume holding the lock button down is to store the code of the keyfob into the ecu.  I did hold it down for a good 12-15 seconds both times.

All fuses were checked because we suspected an issue with the glow plugs.

Fault Codes:
P1113 Intake Air Temperature (Sensor was unplugged)
P0193 Fuel Pressure Sensor "A" Circuit High (Appeared after using an electric pump to bleed the system.  Manual pump was ineffective due to being new and full of air.)
P0104 Mass Air Flow (Sensor was unplugged)

Prior to starting work:
P0402 Exhaust Gas Recirculation "A" Flow Excessive Detected
P3008 Unknown (Turbo/EGR from what I remember)

The turbo was also replaced along with oil pickup, feed pipes etc hence the previous fault codes.

Our first thought was an air lock in the fuel system but we have spent several hours bleeding the system and removing one injector had fuel spraying out at regular intervals.

Hi, did you sort it, what was it?

Hi,
I have since purchased a new van as the turbo has failed three times in approx. 55k miles.
I could not get it started and believe the fault is due to the injectors being mixed up when the injector seals were changed.
Therefore the injectors must be coded on this vehicle, which my mechanic wasn't aware of at the time.
The van started every time before stripping it down so it is highly likely to be the immobiliser.
I have not had time to have the injectors coded and the MOT has expired, more work needs doing etc etc once the van is running again so tro be honest I have given up with it.
Lesson learnt - change the injectors one by one, or mark them.  I did them myself the first time the turbo went with no issues.
Thank You everyone for your help though, it is much appreciated.

don't know if i remember this correctly but doesn't that depend on what make the ecu is as i swopped complete engine -injectors and all, but didn't need to recode the injectors, mines on a bosch ecu

Hi mate sorry to here of your woes.

The injectors are not coded on the 1.6hdi so it does not matter if you mix them up.

Also they can be an absolute Ba***rd to start if the fuel has run back ive had the same problem myself! I spoke to an RAC guy on the matter because i thought i was going mad when i could not get one to start and he said they hate them and they can refuse to start for no reason! He stated that towing them is the only answer with some of them. He also gave me a word of warning he said never disconnect and on the injectors when the engine is running - eg the old way to find a defective injector - because one of their patrols did it and it blew a hole straight though the piston!!!!!!! He said they had had a memo to this effect! His general opinion of 1.6HDI's was not good he generally hated them lol

(12-02-2015, 02:30 PM)polar Wrote:  Hi mate sorry to here of your woes.

The injectors are not coded on the 1.6hdi so it does not matter if you mix them up.

Also they can be an absolute Ba***rd to start if the fuel has run back ive had the same problem myself! I spoke to an RAC guy on the matter because i thought i was going mad when i could not get one to start and he said they hate them and they can refuse to start for no reason! He stated that towing them is the only answer with some of them. He also gave me a word of warning he said never disconnect and on the injectors when the engine is running - eg the old way to find a defective injector - because one of their patrols did it and it blew a hole straight though the piston!!!!!!! He said they had had a memo to this effect! His general opinion of 1.6HDI's was not good he generally hated them lol

You can't disconnect piezzo injectors. They can stay opened and fill the engine with diesel. Piezzo injectors need electric pulse to close fuel!
On "old" type injectors electirc pulse is used to open it , when the pulse ends , injector closes fuel.

Best regards,
brajomobil

braj, that'e filled a hole in my knowledge and answered many questions that i've pondered over in the past
lrb