injector fault - error df053 1.5 dci 2005

[donmanuelmagno]

Hi all,

I must say first of all the information you´ve shared in this forum is priceless!

The story of my car... bought it couple of months, a 1.5 dci with 65k miles on the clock and full service history.
4 weeks ago I replaced the cambelt, auxiliary belt and water pump as it was time.

2 weeks ago, after the weekend, it took longer than usually to start, but I thought it was related with the weather; but the issue became more obvious every day it passed, to the point it took a couple of attempts to start the engine. then the injector fault + STOP message appeared in the dashboard for a couple of seconds while driving and dissapeared.
After 4 days of issues with starting the car refused to start with the same message appearing on the dashboard (injector fault + STOP).

Knowing the delphi pumps of that time were reknown for their ability to break down, I replaced the diesel filter and I only found clean diesel and no metal particles ( which was a relief), so I decided to do an injector flow test. I found 1 and 4 gave a greater return, so I took them all out and cleaned them with acetone and ether (by letting the tip to soak in the solvents). New washers and the injectors back made the car start with no problem. I drove it 20 miles or so and went back home. 2 days after refused to start again by cranking.

If I use carb cleaner to start, the car will start and run "fine", with a clicking noise from the engine. Today the mechanic plugged the clip and it returned the error code df053, related to the rail pressure. The mechanic believes it is either air coming in through the HP seals, pipework or knackered injector.

I don´t see how a blocked injector cannot let the pressure to reach the level it requires to start... but I will do another injector flow test again although I am unsure what it can tell...

Any idea?

cheers!

[grandadbobby]

Hi,
in my experience, l would agree with your mechanic about air in the system. l believe your pump is good, or it wouldn't run. Most likely it is sucking in air at the failing seals. lf it's the first incoming joint, fuel can run back to tank overnight.
lf you are a DIY man, put a clear pipe on the return to tank line to see if there are bubbles.
lf there are, replace the pipe joints one by one with fuel piping till the bubbles are no more.
lt was a cheap fix for me once.
Good luck and let us know if you fix it.
Bob.

[donmanuelmagno]

as a quick update,

I did another flow test and injectors 1,2,4 still give a huge return flow, so I will send them away to test/recondition if needed.

When the car runs, the priming pump is still very soft and I can squeeze it o mater home many times, it will not get hard.

I'll keep you updated


cheers

[fredcamp2]

The 64 dollar question is how does your car start when it reaches running temperature. the hand primer pump on these Renaults do not go hard when the system is primed.

[donmanuelmagno]

I experienced the same starting issues regardless the temperature of the engine...

I am waiting for the Delphi test results of the injectors; if I am "lucky", they will be faulty and that'd be the root cause of the problem

[donmanuelmagno]

(Fingers crossed) I resolved the issue,

I sent the injectors to a specialised Delphi garage and they told me 3 of the were giving a huge diesel return.
After £480, and all reconditioned injectors (make sure you follow their instructions to keep the 12 months guarantee), I installed them and car starts with the first attempt. I drove it today top work, and the average mpg have dropped a bit, but I was told by my mechanic that is normal until I recode the new injectors... which will be the next step.


I hope these posts had the enough information of symptoms and solutions that might be of any use for you guys.

cheers!