1.9 Dci Wont Start - After injector removal

[downsyndromedhorse]

Afternoon,

Removed my injectors today to clean them and have a general check up...

I removed the nozzles and cleaned them out then put it back together and tightened it up. Put it back in, repeated with the others.
I only removed one at a time so i know they are in the right order.

However, with everything back in the right place, it just wont start.
The engine cranks but wont fire.

No air in fuel and fuel is pressured up... No start though?

Any ideas?
Are there issues with removing the nozzles?

Cheers.

[downsyndromedhorse]

Ok a bump and more info...

Removed the cylinder head and the manifold and turbo etc..
The inlet manifold is actually completely gunked up with carbon deposits, probably from the egr before i disconnected it. So this will be cleaned, i need to have the head looked at to have the glow plug drilled out as it got stuck and wont budge.

The injectors seemed ok on the outside however once i removed the nozzles, i found two small prongs on 3 of them, however i injector 3 has two small stubbs where these once were. looks like when it was tightened up they broke off. Could this be the reason for not starting? I didnt think one injector would stop the other 3 working?

Any ideas?

[tomalamix]

did you used the copper washers? you may wrecked the nozzles on the tip if you forgot to use them

[downsyndromedhorse]

Nope they're installed.

I have literally no idea why it wont start. I currently have the engine in pieces to have the glow plug out, once thats done i'll clean everything and put it back together.
Hoping it'll give me a few clues once its back together.
Cheers anyway.

[tomalamix]

if the starter rolls maybe there is something wrong with the rail pressure sensor or some wire loose...

[downsyndromedhorse]

Going to reinstall the head tomorrow, checking all sensors and wiring.
If it wont start, i plan to replace the camshaft sensor and the crankshaft sensor, as they often cause major headaches with starting. If still no start the injectors will go to a specialist i've found. If still no start then i'll set fire to the car

[tomalamix]

dont burn it yet...i need a crankshaft for mine

[downsyndromedhorse]

Reinstalled everything, struck up first time!
Smoked like hell though. Checked the timing and all gaskets and seals, everything is fine.
Went for a drive to clear it out and it didnt, instead it lost all power!
Literally wouldnt drive. Found the egr had blasted itself out! My friend had installed this and not bolted it in right. Anyhow, reinstalled it and it drove better, but now there is no boost, as if the turbo wasnt working. But i can hear the turbo spooling and wastegate woosh. It doesnt seem to kick in though. And its not smoking any more! Im stumped.

[downsyndromedhorse]

Forgot to reconnect the wastegate solenoid! D'oh. Back to smoking again now. Intend to retime it as I'm sure that's the cause!

[tomalamix]

time for turbo ckeck: radial play it can be only a very few inchs and the axial play should be 0 ZERO for a KKK turbo. the car idles ok with no smoke?

[downsyndromedhorse]

Turbo is spot on, no problems there.
However i think we've nailed the problem, pulling into my drive earlier, the temperature shot up... Coolant had gone bye bye, but no leaking!! So, sadly it appears my head gasket is caput! Will be removing the head (again) tomorrow and replacing it on monday morning, good job im off for a few weeks!!

Going to cut the Cat out at the same time, egr is spun around to disable it and crankcase vent is now running into a filter instead of my intake: I want my engine staying clean from now on!

Will update you on my outcome once i've rebuilt her, again! Fecking thing.

Cheers mate.

[tomalamix]

beware and check for head and block distortion. renault says that the head cannot be skimmed, but everyone knows it can. from my experience this engine heads are very reliable in what it concerns to temperature issues, although sometimes failures like glow plugs or injector splits up and screws up the engine head from inside, the piston and possibly the combustion chamber area. Ive performed a skim for a 0,7mm (too high). After this the engine only did idle, you could press the pedal all the way down but the revs didnt go up. New head, same valves, same injectors etc etc and the engine returned to normal, revving up normally and temperature on the spot. Skim carefully if needed and in a reliable professional.

good luck

[downsyndromedhorse]

Cheers dude, took the head off this morning. Gasket had gone, split the layers and allowed oil and coolant to mix. Explains the smoke i suppose!
Picking up a new gasket set tomorrow and rebuilding. Will get the head checked in the morning, though it looks good to me.

Thanks for your help so far

[tomalamix]

use a plain bar to put it on the top of the head and do the same for the engine block. for your engine i dont know what's the maximum distortion, but just for guidance there are 1.5dci that the maximum is 0,03 mm and others is 0,05mm, renault data. I would say 0,05 as standart you will be fine. i advise you to change the head bolts to new ones, their not a fortune and avoid a new failure again.

good luck

[davelowe]

Renault state that the injector pipes must also be replaced. Why on earth did you remove them in the first place?! I'd leave well alone in the future unless you have good reason not to (but when has that principle ever applied to me)