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[Engine] 2003 Berlingo M59 DW8B no start (SOLVED)
#31
Oh christ with this cursed piece of automotive heap.....

Bought new shims, all back together - all intake valves at 0.2mm

Aaaand....no start

I'm beginning to suspect if the HPFP is making enough pressure to actually open the injectors.....
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#32
So, I decided to pull the exhaust off straight after the manifold, there must be some fuel getting to the cylinder as I have white smoke coming the exhaust manifold.

Also swapped to clear tubing from filter - no air bubbles at all present.

Cracked each injector pipe once more and gave approx 5sec crank per cylinder - fuel coming from all of them.

Pulled the exhaust and intake manifold off to check if they're full of soot - cylinder 4 was dirtier than the rest at least.

Gotta order a diesel pressure test kit as I don't have one on hand (or anyone I know)

p.s currently I dont have the pin present for the stop solenoid at all.
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#33
Here's a handy tip for anyone adjusting the valves on these engines.

You can get by without removing the timing belt.

1. remove top and central covers so you have the pump and cam gears in view.
2. zip-tie the belt to the pump and cam gears.
3. put a bolt through pump and cam timing holes (M8 for cam / 6mm drill bit or bolt for pump)
4. undo the cam gear central bolt (16mm)
5. attach a bungee cord to the gam gear tension somewhere you like - i used wheel bolts
6. remove the cam timing hole bolt
7. tap on the gam gear lightly to slip it from the slotted cam hole
8. proceed with undoing the bolts from the cam (undo evenly, cam is pushing on some of the valves, dont just yank them out)
9. place new shims under buckets
10. slip camshaft back to cam gear, hand tighten the 16mm central bolt and check that everything is the right place
11. tighten camshaft gradually to spec
12. place the M8 bolt back to the timing hole
13. re-check and tighten everything to spec (remember that hand tightened 16mm cam bolt)
14. rotate engine a couple of times and check clearances again
15. check that everything is still lining up.
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#34
So, looks like I got the damn thing running!

A truly awful air lock inside the fuel pump must've been the cause.

Got my mate to help me out and towed the car for some time in 3rd gear at around 35km/h (about 20mph)

The thing was bucking and shaking like hell, would die instantly when taking out of gear - eventually after about a mile / 1.5km pull it just wouldn't die anymore when taking it out of gear.

Seems to be idling fine (quite high idle though, around 1K rpm even after warming up)

Just had a quick try after it had been sitting for the evening and the night - fired up on it's own quite happily this morning.

Could also have been some wax from the frozen summer diesel lodged in the fuel pump.....

Still gotta attach the stop solenoid pin, exhaust and some timing covers
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#35
Nice.
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#36
Both our DW8s had a high tickover speed, around 900rpm I seem to remember

Peter
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#37
If you'd filmed all this, you could have had an interesting little youtube channel.... Smile
Work van:     2020 1.5 BlueHDi 100 Enterprise Berlingo
Spare van:    2001 1.9 600d Berlingo
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#38
(11-02-2023, 09:25 AM)notsofast Wrote:  If you'd filmed all this, you could have had an interesting little youtube channel.... Smile

You're telling me mate! Would've made the cars value with ad revenue  Big Grin

Maybe split into 14 parts of "Restoring old van, you ain't gonna believe what it takes to start!!"
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#39
Wanted to revert back to you all fine folks here and thank you for the replies.

Finally got myself a new stop solenoid Meat & Doria part #9000 and it's waiting to be installed this weekend, just gotta decide where to pull the power for it!

The cars been running like a dream, starts on a dime! I can't even hear the starter engage before it's up an running even when the temps dropped during the night to -15C (valve adjustment, new glow plugs, full fuel system cleanup and injector overhaul must've done the trick)

Still got some things to take care of though...

- Wax stat that controls the idle - It's stuck so that's gotta be replaced
- Front passenger side spring is broken (driver side for you monarchical folks)
- Steering rack boot is shot


There was a strange sound coming from the rear and I was sure the bearing or the axle was shot! Turns out someone swapped an axle from a Berlingo with ABS and the abs ring was broken and made contact with the handbrake mechanism...

Quick cleanup on the rear brakes, hammered out the remains of that ABS ring and all good Smile
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#40
Well done, I feel less of a masochist tearing the 16v hdi apart at the moment.

It's worth repeating about the inlet valve clearances on older pug/cit diesels closing up.

The 106/Saxo TUD5 I had did this.
Zero clearance on the inlet valves when checked at 100,000 miles.
When cold, the aluminium head shrinks more than the steel valve, propping them open, hence mysterious no start when cold.
Runs perfectly once warm.
The exhaust clearances were perfect, probably still perfect when rust claimed the car at 205,000 miles.
Its till used no oil, still doing 62mpg at 80mph to the midlands & back to Devon.
Pity I never worked out a good bellhousing to put it in a Morris Minor.
Why do people think French cars are all crap?
198,500 miles,  (Resurrected at 186,000)
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