1.5 DCI Service light under 3000rpm

[Neilht]

Hi all, has anyone had this before on a 1.5 dci 2004 80?

The check injection and service light comes on and off at idle, it stays on whilst driving around but if I full throttle it whilst driving around the light and error message turn off after 3000 rpm and all power is restored!

I’ve just put a second hand head on as cam belt snapped.

New parts are cambelt/waterpump/head bolts/gaskets and all filters/plugs/oils/clutch.

I’ve checked the timing and it’s good. Fuel pump timing is good, have 18 teeth between cam and pump timing marks etc.

I’ve ordered clip diag to see if any codes are coming up.

Cheers!!

[Neilht]

Well finally got clip working

Faults are camshaft sensor incoherence which is strange as the timing marks Line up fine and there are 18 teeth inbetween cam and pump pulley notches.
But this is not bringing the light on.

Misfire cylinder 4 is bringing the light on but when rail pressure goes high the misfire disappears and fault turns off?

Maybe a dodgy injector?

Or pump timing? Could try lining the wide metal bit of pump sprocket up instead of the notch?

Any help appreciated, will strip no4 injector tonight

[Neilht]

Well moved the injectors round and re coded them.

Error has traveled with the injector so I’m hoing to strip it and clean/refit. Fingers crossed.

Still want to sort out the cam error if it is still there after fixing injector so will have to check timing again.

Looking at the crank timing pin length is it possible it’s been machined a bit too long/short by 1mm? Is it possible the small difference would throw timing out?

Cheers

[Neilht]

Well injector stripped/cleaned and problem has gone!

Still got cam sensor incoherence error so need to check timing tomorrow.

Also fuel feed line is depriming after fitting a aftermarket filter guess it’s a sh1t one

[Stranger]

Good news on the injector

Best of luck with the cam sensor error and fuel line

[Neilht]

Well grabbed 2 priming bulbs from the scrapyard for £5 which has sorted the depriming issue!

And found the pump timing out by about 180 Deg due to a rouge tippex mark on the pulley! Lined it up on the notch and now starts fine with no codes!

Happy days!

[Stranger]

Excellent!