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        General >> Problems >> rrr-rrr-rrr-rrr-brum!
        
(Message started by: sector-9 on Apr 18^th, 2006, 10:21pm)

Title: rrr-rrr-rrr-rrr-brum!
Post by sector-9 on Apr 18^th, 2006, 10:21pm

I think my evil hell of a service (see: is this a joke!?) has actually not helped at all.

First off, this morning when I got to work I noticed there was steam coming out the side of the bonnet. That was easy enough to trace - the main feed pipe from the bottom of the expansion tank had split at the screw clip (I had to remove it along with the bottom hose to get the rad out). Sorted that one in my dinner break.

However since doing all the work, it is now taking several seconds of cranking before the engine will start, even when hot which I assume rules out the glowplugs. Incidentally I did a current check on each of them - they varied between about 14 and 18 amps apiece. Somebody did previously mention something about injector advance and I have unplugged and cleaned up the contacts in the two engine loom multi-plugs; however that should make things better not worse! Also the engine seems to have less power than previously and I think is doing even less mpg >:(

The other thing I did was the change the fuel filter, but I didn't have any clear plastic tubing to bleed the system with so did it the best I could without. However it has been to Coventry and back yesterday, some 130 miles round trip so that should have got rid of any air trapped.

Finally, the EGR valve still does diddly squat, despite getting voltage to the solenoid.

Anybody got any ideas? I'm not fully comp so I have to fix it...

Darren

Title: Re: rrr-rrr-rrr-rrr-brum!
Post by mazzy_j on Apr 19^th, 2006, 11:25am

Darren, I see you are located in Nottingham, at the weekends i'm in Leicester which isn't a million miles away so you're quite welcome to come have a look at my diesel and see what the 2 engines do differently. When i changed the filter on mine i didn't use any tubing, i just disconnected the hose from it and pushed the primer until fuel started to come out and its been fine.

I also have a spare EGR pipe if you want try that.

Matt

Title: Re: rrr-rrr-rrr-rrr-brum!
Post by sector-9 on Apr 19^th, 2006, 8:27pm

Thanks for the offer - I may take you up on that if I can't improve things. Tonight it seemed to idle quieter than it has done after the service, but is still taking ages to start. Having said that, it could be the glowplugs because when it does fire from cold it is very rough for the first few seconds and gradually gets smoother. Of course, that could also signify air in the system!

Does your diesel smoke when you rev it hard? Mine doesn't seem to smoke at all, even revving to the governor with it stationary. Wondering if a previous owner has played with the pump settings, but I'm loathe to just try fiddling with them in the hope it will improve things...

I did try unplugging the two engine loom multiplugs with the engine running - the top one killed it dead instantly so must have the wire for the fuel shut-off solenoid, the bottom one makes it really noisy when idling. Unplugging the CTS, TPS and advance solenoid all give a change in engine note so I assume whatever they're supposed to do they are.

If I pull off the top pipe on the EGR solenoid (marked ATM) and plug the nozzle with my finger the EGR valve opens fully. I can also feel the vacuum pulsing until it does. Perhaps it's a busted solenoid valve???

Darren

Title: Re: rrr-rrr-rrr-rrr-brum!
Post by mazzy_j on Apr 21^st, 2006, 9:52am

If i rev it hard whilst stationary it 'puffs' briefly (presumably because a load of fuel has just been dumped in to the cylinders and can't burn off) but doesn't smoke as the revs rise. At night if i were boot it with a car following behind i can see a fair amount of smoke in its headlights being chucked out, but if i were to do the same during the day it just gives a light 'dusting' of smoke to whoevers behind, nothing major though.

Matt

Title: Re: rrr-rrr-rrr-rrr-brum!
Post by sector-9 on Apr 21^st, 2006, 7:09pm

That's a relief! I only notice mine smoking at night - again in somebody else's headlights. Haven't noticed any smoke at any other times (apart from blue on startup) so wondered if somebody had been playing with the pump...

It's still a pig to start, but I'm going outside in a mo and I'll check that the glowplugs are getting power. If so then the only other thing I've touched which may affect it is the fuel filter. Thanks for the info though - at least I know it isn't abnormal now!

Darren

Title: Re: rrr-rrr-rrr-rrr-brum!
Post by sector-9 on Apr 21^st, 2006, 10:50pm

Well I think I've found the cause of bad starting - the fuel filter I put on last weekend is leaking. Obviously it is draining some of the fuel out and is having to re-prime the system every time it starts :( At least I can fix that simply. Glowplugs are getting power fine.

Have also switched polarity on the small (RH) cooling fan - they both now suck air through the radiator. Finally, I've gotten somewhere with the EGR solenoid. Basically if I earth the black/green (or is it black/blue?) wire the EGR valve opens fully. This rules out the vacuum part, solenoid valve and power feed. Only problem is it that the ground wire is switched by the ECU so it's either that or the loom (again!)...

Darren

Title: Re: rrr-rrr-rrr-rrr-brum!
Post by sector-9 on Apr 22^nd, 2006, 5:18pm

Sorted out the bad starting and it was the fuel filter leaking - apparently the large rubber O rings are slightly different sizes - the larger one goes on the top of the filter and the smaller one at the bottom. Me clearly being a muppet, I'd put them on the wrong way around so that the filter was leaking from the top seal! :-[

Anyhow, car now starts fine (well, as good as it used to), runs quieter, fans runs properly and I've even replaced the reversing light switch (got an earlier one which is totally different inside and out but works anyhow). Just need to fix the EGR problem now and it should all be sorted...

Darren

Title: Re: rrr-rrr-rrr-rrr-brum!
Post by mazzy_j on Apr 24^th, 2006, 12:06pm

Thats all good to hear ;D I'd personally leave the EGR disconnected as i don't like the sound of my engine eating its own poo ;)

A few weeks back i took the inlet manifold off mine to replace the gaskets to find it completely gunged up inside the poor thing (no thanks to the EGR dumping soot and general exhaust crap into the manifold), used a chemical cleaning machine at work (like a bigger version of what they use in garages to remove brake dust) to do the equivalent of a colonic to remove all the crud inside. Took 20 minutes it was that bad!! Car now pulls stronger, gets more mpg, and smokes less too with the EGR disconnected 8)

Matt

Title: Re: rrr-rrr-rrr-rrr-brum!
Post by sector-9 on Apr 24^th, 2006, 11:19pm

Interesting! I did some google searches for EGR systems and the result I found which explained it in enough detail said that a well-designed and functioning EGR system can improve economy; of course, the lower emissions would also be nice.

I do remember doing a head job on an Escort 1.8TDi engine (snapped belt, bent valves - usual story) - the EGR pipe on that was full of a greasy, tar-like crap which took plenty of cleaning with old rags and stiff wire. I'm hoping that my low-mileage engine will have escaped that fate though. :-/

TBH, I can live with the EGR valve staying firmly shut, but I'm one of those people who like to have everything 'just right' - even if just right isn't what's best! Mind you, I think I (with the help of some very knowledgeable chaps) may have sussed out the problem with the EGR system. Read the "brain surgery" post when I get around to writing it. 8)

Darren

P.S.

Doubt I'll get the same mpg you've been getting though; think mid thirties is about the best I can hope for...

Title: Re: rrr-rrr-rrr-rrr-brum!
Post by mazzy_j on Apr 25^th, 2006, 9:26am

I think i found the exact same site you found when my EGR was playing up and i was looking into how it works/what could be up with it.

I know what you mean by the 'just right' feeling, but after i saw the state inside my manifold there was no way that little innocent looking vacume pipe was going back on the EGR!! Talking of emmisions, my car runs on biodiesel so its (as good as) carbon neutral anyway :)

If you want to check the condition just take the inlet pipe off and shine a torch inside and have a peek, my car has 3 times more miles so yours shouldn't be too bad :)

Matt

Title: Re: rrr-rrr-rrr-rrr-brum!
Post by sector-9 on Apr 26^th, 2006, 9:55pm

Woohoo! All sorted now - EGR valve working as it should (presumably - it opens and closes), fuel and coolant leaks stopped, fans fixed, boot release fixed, air-con running, reverse lights, front light - the whole lot. Hopefully I can now start enjoying the inside of the car, not just the underside of it!!! :D

Darren