[Engine] Help please 1.9d NOW SOLVED!!

[Oli89]

Right I just tried starting it with my mate pumping the primer, result it tries to run but still won't idle I'm fairly confident that this means I have an air leak , new filter bowl has been ordered, hopefully know by this afternoon!?

[geoff]

Place a new fuel filter in the system at the same time ...... sucking eggs of course !

[Oli89]

Ok now I'm stumped, I have replaced the filter housing and element, all vacuum hoses are where they should be as far as I can tell and the butterfly valve is open, it still only fires and then dies .. admittedly it fires a bit more readily but still dies almost immediately.
There's no water in the oil or vice versa so would be surprised if it's lost compression , no nasty rattles when it turns over so doubt the timing belt has jumped
I have primed the system as described in the Haynes manual, but this just involves pumping the primer.
What am I missing?
Any ideas where to go from here?

[geoff]

Look at Haynes 4 B3 section 2 which describes bleeding, it say some models have a bleed point at the pump see if yours has one. There are a number of steps requiring action, too much for me to type out.
Read paragraphs 2 through to 8

Been a few years now but memory tells me to follow the clear pipe to the pump and the bleed point is at that point.

[Oli89]

Managed to get it started towing it. Idles ok but won't rev seems to be running rich causing the egr to open when you rev it and knocks when you rev aswell, possible timing issue? How likely is it that the cam belt could have slipped and it still starts? Is there another way the pump timing could have changed?

[geoff]

Firstly take the egr out of the equation by removing the two vacuum lines running to it and plug them, simple quick job.

After that it my be worth checking the timing belt cam and pump alignment, not a quick job.

[THE BADGE]

Hi Oli89,
Welcome to the forum,
I had a similar problem with my previous Berlingo, air in the system can be a nightmare, but don't panic, hopefully this will cure it,
prime the pump by pushing up & down until you feel a resistance, this will probably only be slight because air is still trapped, with someone cranking the engine - crack open the injector banjos, one by one until you get diesel coming through, this worked for me, by the time I had undone the third one the engine was running, & after a few minutes all the air was expelled, 
I hope this works for you, my priming pump used to get wet too, as long as it's not pouring out, you should be ok.

[Oli89]

Guess what it was! A blocked catalytic converter, creating back pressure and forcing the egr valve open when you try and rev it ! Thanks for all the help!!! Really appreciate it ?

[geoff]

Thanks for feeding back to us with the solution it will surely help others along the way.

How did you work it out ??

[Oli89]

Removed an cleaned egr valve , then refitted it, this made no difference an the egr was obviously still operating when it shouldn't. We then disconnected the exhaust feed to egr at the egr end and tried it ....fires straight up and runs lovely ... fabricated and fitted a blanking plate to fit between exhaust feed and egr....ran it again ... won't rev and now the she is not operating I'm now suspicious the exhaust is blocked..... reinstated egr valve and removed exhaust from behind first silencer ..... started it up again , no problems runs and revs without so much as a cough and egr no longer opening when it shouldn't. I'm assuming because it was sat for a while before I bought it the spirited run I gave it must have dislodged some crap in the cat that's then partially blocked the flow.

So relieved!