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[Engine] engine swop 1.6hdi 90 won't run
#1
Hi All. 2008 berlingo 1.6hdi 90 800 van
Just put another engine in, complete, same engine code, from local breakers but won't start. Turns over ok, seemed to bleed up ok but no fuel at injectors,after a few attempts to start it changed the valve? on top of the hp pump to the original one (two pin plug to it) in case it was coded but still no fuel.
Glow plug light doesn't come on when ignition turned on.
Original problem was rod through side of block.
Plugged in code reader,  got dtc's p1162, p0490,p0409,1093,p1351, wiped it and got p0193 and p1351.  
Bought online manual from emanuals took 36 hrs to download, wouldn't run on my XP laptop, got help from emanuals and got it to run, doesn't cover this model properly, personal opinion is total crap and waste of 2 fustrating days in total,.
Any help appreciated.
,
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#2
First things first change the fuel filter, p0193 can be related to this.

Plenty of fuel in tank?

Getting power to hp pump?

Injectors blocked?

Exhaust not blocked anywhere?

Did you use your old ecu and immobiliser?

Does the key symbol go out?

Which injectors did you use? Different ones if you are using your old ecu might need coding.
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#3
(21-10-2014, 03:15 PM)homeruk Wrote:  First things first change the fuel filter, p0193 can be related to this.

Plenty of fuel in tank?

Getting power to hp pump?

Injectors blocked?

Exhaust not blocked anywhere?

Did you use your old ecu and immobiliser?

Does the key symbol go out?

Which injectors did you use?  Different ones if you are using your old ecu might need coding.

Tank 3/4 full,
Filter appears to bleed back to tank ok so guess it's not blocked and ran fresh engine before it was removed,
No fuel getting to injectors,
Engine just removed from van ran fine till big end came through cranckase,
Have not changed ecu and immobiliser - why would I?
I used injectors that came with fresh engine
coded? that's one of the questions I hope to get answered here ' and is anything else coded that needs swopping?
Key symbol doesn't come on
Also glow plug light daesn't come on
Engine warning light does but guess that's normal if engine isn't running
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#4
(21-10-2014, 06:54 PM)landroverbob Wrote:  Have not changed ecu and immobiliser - why would I?
I used injectors that came with fresh engine
coded? that's one of the questions I hope to get answered here ' and is anything else coded that needs swopping?


You have to code the injectors with lexia. Or if you have autocom cdp+ or delphi diagnostic.
Read out the code from top of injector and write it to ecu...

But again you don't have key symbol on dash ?! hmmmm...
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#5
(22-10-2014, 08:09 AM)brajomobil Wrote:  
(21-10-2014, 06:54 PM)landroverbob Wrote:  Have not changed ecu and immobiliser - why would I?
I used injectors that came with fresh engine
coded? that's one of the questions I hope to get answered here ' and is anything else coded that needs swopping?



You have to code the injectors with lexia. Or if you have autocom cdp+ or delphi diagnostic.
Read out the code from top of injector and write it to ecu...

But again you don't have key symbol on dash ?! hmmmm...

Thanks brajamobil
I've ordered Lexia should be here in a few days so will be able -I hope- to code injectors. Would that be the reason that there is no fuel getting to the injectors? Any more sensors etc coded to the ecu?
lrb
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#6
Although the injectors need coding to the ECU it is my understanding that it should run although less efficiently if they are not.
Check all the engine wiring and buy a can of easy-start.
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#7
Change fuel filter.

Check hp pump is working.

There is not much to check if fuel isn't getting through.

Have you done a leak off test?

John m is correct car should run, have you considered fitting the original injectors off the knackered engine?
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#8
(22-10-2014, 09:39 PM)JohnM Wrote:  Although the injectors need coding to the ECU it is my understanding that it should run although less efficiently if they are not.
Check all the engine wiring and buy a can of easy-start.

Hi, runs on brake cleaner but not on it's own fuel supply, fuel not coming out of injector pipes although mateys launch diag says there is 330 bar at cranking. ( didn't have it long enough to try with injector pipe disconected even if I'd been intelligent enough to think of that.Wondered if hp pump can airlock. Next chance I get I"ll be undoing pipes to and from hp pump. Was waiting (impatiently) till Lexia arrived before another session on fault finding, should be here tomorrow if I'm lucky. Any suggestions considered as to why no fuel fro hp pump, wondered if pressure sensor was faulty so may swop that tonight but still don't know what the immobiliser shuts down and would love to know if anyone can tell me that
lrb
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#9
leak off test, can you suggest how you would do it on this van.
If I've got no air in fuel return to tank when priming would that mean system is purged? There is a solenoid with three wires to it on the top of the hp pump, I swopped that for the original one - is that a shut of valve thats not opening now - poss how the immobiliser works too? I've not thought of that till now but three wires confuse me. I'll look at the removed one later today
lrb
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#10
All sorted, when the plug was pushed onto the sensor on the end of the fuel rail the pins got bent so it really was open circuit as scanners had indicated. Inside this plug is  a red plastic rectangular part that had pulled out and was left inside the old regulator without which the plug was able to be pushed in at an angle, looked like it was in ok best you can see using a mirror. I swopped the fuel regulator anyway using 1/2" drive, deep 27mm  injector socket and u/j + 6" extension after taking battery tray off for access.
Nothing needs coding or changing for this swop and I found out from chap who fitted it that it was from a picasso, probably newer and several brackets had to be changed -aircon to non aircon for one, bottom pulley too but not sure if that wasn't just to give it more clearance to the chassis when fitting back in. I also noticed part of the wiring loom is lying on top of the auxiliary belt pulley, protection sheath missing,  may have been incorrectly routed but obviously will be attended to.
There is still a dtc present referring to the glow plug supply, I parted the multiplug and checked the glow plug side and all pins were showing a circuit to earth but will look more at that before I put the battery tray, air filter and pipes back on, looks a bugger to get at some of them. The engine started ok without them but it's still in the 20's here at not cold.Hope Lexia will tell me more -later.
Lexia came -very good delivery time from easydiagnos, paper loading instructions I used that came with the kit/disc are not child proof so probably cocked up there, later on opening disc I found a utube type instruction video for loading the software which I gave up on as I couldn't re-load and read video at the same time. It did work after a fashion, read the dtc's just as blue point and launch did though I expected more and didn't get individual component actuating to the level I expected but I was rushed and don't want to be unfair to the suppliers or the makers. It wouldn't exit the programme either but I guess I got something wrong and have now removed the software from my laptop and am going to reload it. Like most of us this is done at night when suppliers are closed so can't just ring them, feedback is they are helpful but we'll see. Can't access their website as a 'member' for help yet as did the log in etc but it won't recognise me as a 'buyer' and give me full access but I'm on to that too. Not now as it's 11.30, saturday night and it's bedtime.  
Personally with all these things I need real accurate step by step and easy to follow instruction and find often "it's a miracle" when they work. Didn't see any operating instructions for use on the car yet either. Lot's of peugeot / citroens here (france!!) -got a 307 and 406 myself - both with issues so will be getting practise in.
Tomorrow is mend the strimmer day - chinese carbs - oh joy but followed by play on the dirt bike I hope  
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