406 HDI GLOW PLUG RELAY

[madmadmax]

before you dive in and spend a lot of money get sum diesel in a bucket and put a pump in it get sum piping and run it from the pump in the bucket to the fuel filter

feeds have the white tab returns are green you can leave the returns connected to the car

i only suggest doing this as i don't think is a hp pump problem as the fuel filter id not getting the presser it needs so may be a blocked pipe

[womble171]

Thanks mate , will definitely give that a go. I have had the head of the filter off and you can see the bowl filling up, I have also took the injector pipe off that goes from the hp pump to the fuel rail off and turned the ignition on and I am getting a fine pencil like steam squirting out of the hp pump. I was gonna whip an injector off and see what I am getting at the source? If it is over fuelling on an injector can that stop it from starting?

[womble171]

I couldn't find any tubing so I cracked each pipe off at the injector and I am getting a stream of fuel to each one. Don't know if it's supposed to come out with any force but this isnt, it's just a constant flow

[madmadmax]

its not the injector pipes these should never lose whilst the engine is being cranked as there is 250bar there at cranking this will cut metal, bone and keep going

its the pipes to the fuel filter from the tank that i think have a partly blocked thus reducing flow and presser

and the fuel to the injectors rules out the hp pump

if the hp cart get 250 - 300 bar at the fuel presser sensor(the one on the fuel rail) it will not start

do you have a lexia?

your in injectors should have a resistance of 600 milli ohms

[womble171]

Sorry, don't have lexia just a universal obd reader.
Just tested the injectors and they are spot on with the readings you gave me. I am definitely not getting bone cutting pressure at the injector, not even paper cut pressure! I have just took a little vwideo of the ignition getting turned on with the injector pipe off and then cranking it over as soon as I find out how, I will post it on here for you or post a link to YouTube.

[madmadmax]

could you also get a measurement of the amount of fuel that is pumped during the priming proses

[womble171]

I would only be able to divert the fuel into a jug or something similar and give you a fluid measurement, i dont have anything to pressure test it with.

Here is the link to the video of it on ignition and cranking..
http://youtu.be/qH2hybOsC2c

Its pretty much the same on all four injectors

[madmadmax]

getting the fuel flow is just for comparison to a running one and to see whats going on

[womble171]

I will take a measure in the morning. The pump runs for about 3 seconds when you turn ignition on, I will pop the flow from the tank and divert it to a jug. Did you have a look at the link? Does that look normal?

[steve_earwig]

That certainly doesn't look like 120 bar

[womble171]

Any ideas Steve? Are we on the right track with madmadmax with there being a blockage somewhere or could it be something else causing the problem? Am I right in thinking that it shouldn't come out of the low pressure pump with such high pressure (hence being called the low pressure pump)? I have another lp pump and pressure regulator, I could always see if I am getting the same symptoms with them swapped over?

[steve_earwig]

The lp pump is regulated to something like 0.7 bar, which could be what you're seeing there. The ecu won't even fire the injectors until the pressure is more than 120 bar, which is a long way from what you're getting. So either the pressure regulator is stuck open (I think that's how it works) but you already covered that, something is robbing the system of pressure (an injector stuck open or dumping all the pressure back to the tank via the leak off), there's not enough fuel getting to the hp pump (blockage?) or the hp pump itself is goosed.

I presume you saw this viewtopic.php?f=10&t=10971&p=97493&hilit=120+bar#p97493

I did come across a thread on the fcf (I think it was) earlier where the guy was getting similar problems to you and it turned out the valves on the fuel feeds inside the hp pump weren't seating so it wasn't developing enough pressure, however before it died completely it was running very rough and surging.

[lozz]

The Lp pump look's like its doing its job.

Have you mixed the pipes up on the fuel housing by any chance,?
not say'ing you have but,its worth a check,.

[womble171]

Thanks Steve.

I am just in the process of checking the fuel lines now, will take some pics an keep you all posted. From wat I can see, the main fuel intake comes in on the right side of the filter bowl, then I have a flow on the bottom right and return on the bottom left( as you look at filter), then it's the flow on the top right and return on the top left? I have just blew the top right on off that goes to the pump and that's clear(well seems to be)? I am getting a stream of fuel coming out of the return on the pump which is connected to the left of the filter head but no pressure? I have only tested both pressure regulators by the ohm settings on auto data, is that reliable or is there another way to test it? The car was running fine before it just packed in, in fact I went from Liverpool to Kent nd back and it ran like a dream( well on the way back it did as I had a sticky turbo waste gate on the way there?

Can you get thehppump off without throwing the timing out? Any hints on how to remove it please?

[lozz]

That flow dont look right,
even before you crank the engine youve got aflow from the lift pump going to the injector pipe,