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 Posted: Mon Feb 03, 2014 10:16 am |
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Joined: Feb 24, 2010
Posts: 2596
Trade Rating: +17
Location: North West Wales
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Bought a 2L HDi Y reg 2001 pre plex a few weeks ago cheap knowing it had an issue with starting. At the time I was told it was the high pressure fuel pump & was given a known good one with the car. So Changed the pump and at the same time flushed out all the fuel lines & filter housing and dropped the tank and cleaned that out. Put it all back together, fresh diesel & for a couple of days it was starting pretty much first turn of the key without fail.
But slowly the same problems coming back of turning the key & the engine will turn over and over and just not fire. It can take 2 or 3 turns on & off they key and holding it for a while before it will fire. Sometimes pumping the throttle does help as well.
When the car is stone dead cold 9 times out of 10 it will start on the first turn of they key & the engine turning over within 2 & and a half times. It seems to play up more when it's up to temp. If you switch it off & try and start it immediately it will fire. But switch it off and leave it a couple of minutes and it becomes an absolute nightmare. But when its hot & its just turning over it seems to be easier when connected to another car on jump leads.
Not sure what to go about checking next. Hoping it's not an injector issue, but I can't rule it out either.
Anybody got any ideas what I should check next?
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Posted: Mon Feb 03, 2014 10:30 am |
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Joined: Feb 24, 2010
Posts: 2596
Trade Rating: +17
Location: North West Wales
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Just one thing I've just tried, went to it now after it being stood overnight stone dead cold. Put the multimeter on the battery it was reading just over 13V with nothing on, soon as I flicked the ignition on it dropped down to 12.5/12.6 & as soon as I went to start it it dropped down to about 10.5 but it started straight away with no issues at all. When running it was idling at about 14.3/14.4 V
Turned it off and tried to start it again and it started again no problems but when the started was engaged there was still nearly a 3V drop on the battery.
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Posted: Mon Feb 03, 2014 1:06 pm |
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Joined: May 16, 2011
Posts: 495
Trade Rating: +1
Location: huddersfield
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Hi Lee, a common fault on the 2ltr hdi is a yellow plug at the bottom of the engine, below the oil filter, which goes upto the rail pressure sensor, the yellow plug in question was a design flaw and is not fixed down.
The 3 wires in the plug can become frayed or develop a bad connection, can cause havok starting problems etc.
Worth checking.
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| 206 2ltr Hdi glx 53 plate | |
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Posted: Mon Feb 03, 2014 3:01 pm |
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Joined: Feb 10, 2010
Posts: 4266
Trade Rating: +4
Location: Palestine
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have you thought about checking the glow plugs?
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Posted: Mon Feb 03, 2014 3:13 pm |
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Joined: Jun 08, 2010
Posts: 1035
Trade Rating: +17
Location: North Manchester
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did you reuse your fuel pressure regulator on the rear of the pump ( held by 2x torqs ) or did the replacement pump all ready have one on it ?
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Posted: Mon Feb 03, 2014 5:20 pm |
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Joined: Feb 24, 2010
Posts: 2596
Trade Rating: +17
Location: North West Wales
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| cartoonhead wrote: |
| did you reuse your fuel pressure regulator on the rear of the pump ( held by 2x torqs ) or did the replacement pump all ready have one on it ? |
I had a regulator with the new pump, however with this one it would let the engine start and run for about 4 seconds then cut out. I put the one out of the old pump in which had half the end missing and it started and ran straight away. But slowly the problems been getting worse again.
Cant see it being glow plugs as its more of a problem when the engines warm. Although it can do it when cold as well but no where near as much as on a hot start.
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Posted: Mon Feb 03, 2014 8:28 pm |
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Joined: Feb 24, 2010
Posts: 2596
Trade Rating: +17
Location: North West Wales
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Another update, tonight ive found that it will bump start first time everytime without fail. So this is making me think more about the starter motor drawing too much current that ive read about elsewhere.
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Posted: Tue Feb 04, 2014 2:50 am |
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Joined: Feb 07, 2010
Posts: 7093
Trade Rating: +11
Location: Suffolk
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I would be doing an injector leak off test if I was you due to the metal fillings. Also I would change the low pressure pump, as thats what would have caused the fillings. Not to be a bearer of bad news but its possible that its taken out your new hp pump 
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| Team Impossible Possible
The only way of finding the limits of the possible is by going beyond them into the impossible - Arthur C. Clarke
Forged 1.6 Turbo
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Posted: Tue Feb 04, 2014 7:38 am |
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Joined: Feb 24, 2010
Posts: 2596
Trade Rating: +17
Location: North West Wales
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How do I go about doing a leak off test?
Also just been under the bonnet and found the pump has a slight diesel leak on it somewhere, and it doesn't look like it's from the union I had trouble with either.
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Posted: Tue Feb 04, 2014 9:56 am |
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Joined: Feb 07, 2010
Posts: 7093
Trade Rating: +11
Location: Suffolk
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With a diesel leak tester kit 
Plug the tubes onto the leak off pipes off the injector (the return pipes) and block the original ones. Start it up and run it for about 2 minutes unless one tube fills really fast. They should all put about the same, give or take 10mil
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| Team Impossible Possible
The only way of finding the limits of the possible is by going beyond them into the impossible - Arthur C. Clarke
Forged 1.6 Turbo
Click to see more
144Bhp @ 7PSi - 193.9Bhp @ 13psi
206 Gti Race Car
Click to see more
For all Race/Track Preparation, Feel Free to PM Me!
Whether its for a custom ratio gearbox or track-day alignment, I can help! | |
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Posted: Tue Feb 04, 2014 10:11 am |
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Joined: Feb 24, 2010
Posts: 2596
Trade Rating: +17
Location: North West Wales
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How much does one of them cost?
Anyway can I make a DIY one?
Only trouble is it seems to be refusing to start unless you bump start it now.
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Posted: Tue Feb 04, 2014 11:03 am |
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Joined: Feb 07, 2010
Posts: 7093
Trade Rating: +11
Location: Suffolk
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Or do you have a diagnostic machine with parameters? If so check the pressure in the rail
and you could mate, wont be very accruate though. You need some leak off pipes, and four measuring tubes. Thats it
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| Team Impossible Possible
The only way of finding the limits of the possible is by going beyond them into the impossible - Arthur C. Clarke
Forged 1.6 Turbo
Click to see more
144Bhp @ 7PSi - 193.9Bhp @ 13psi
206 Gti Race Car
Click to see more
For all Race/Track Preparation, Feel Free to PM Me!
Whether its for a custom ratio gearbox or track-day alignment, I can help! | |
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Posted: Tue Feb 04, 2014 11:10 am |
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Joined: Feb 24, 2010
Posts: 2596
Trade Rating: +17
Location: North West Wales
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I have PP so can get all the parameters off that. Will check the fuel rail pressure.
Okie dokie, will give that a go as well, even if its not that accurate it will give me an idea if im barking up the wrong tree or not.
Just had the multimeter on it again as it decided it was going to start off the starter just now. When it's starting by itself the volt drop on crank is under 2V when it's turning over & not firing it's more like a 3V drop.
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Posted: Wed Feb 05, 2014 11:53 am |
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Joined: Feb 24, 2010
Posts: 2596
Trade Rating: +17
Location: North West Wales
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Just an update to this got a new starter from the scrapy today, wacked it on in the car park as I had to pull the old one off there & then so they could match it up. (Apparently there's 3 different types, size variance on the teeth that go into the flywheel) Wasn't too happy with me doing it in his car park but there we go. Meant the new one went on straight away.
Anyhow so far, it's been starting first turn of the key every time so far. Whilst hot which is when it was worse. So just need to let it cool down and see how it behaves. But so far it's been very consistent in the way it's starting and the old motor had some burn marks on the teeth etc.
Thanks for the advice given in this thread and hopefully I have no more issues touch wood.
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Posted: Fri Feb 07, 2014 2:49 am |
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Joined: Feb 10, 2010
Posts: 4266
Trade Rating: +4
Location: Palestine
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Glad that you got it fixed,and thank you for writing back telling us what was the fix,as this will be useful for other members who face this problem.
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