Please Help with this Popping Noise

[zakmuh]

Alright guys, I don't know if I've actually made any progress but I believe I've found two issues with my HP pump.

1. Drive shaft wouldn't rotate easy by fingers. Its stiff and need a pliers to check it. Is this normal?
2. O rings are worn and feels like plastic. Could air be leaking and causing pressure issue?

If it's the o rings, then that is strange cos it car was running all fine and soon after fitting the pump back, its not working. Could this worn o rings cause trouble within like 3 hours?

HP Pump O rings.JPG (99.15 KiB) Viewed 732 times

Thanks

[zakmuh]

Hi

For checking, I put the pump back to engine and did some further investigation. Fuel is flowing to pressuring chamber (if that what it is called?) and pressuring shaft is moving to the cranking. Please see below YT video:



Going to move the outlet side of the pump and see if fuel would get there from here...

[zakmuh]

Looks good.

Hi Rick,

I'm checking one after the other but still no joy.

I think the fuel pump gets switched off by the ECU (to crank signal?) as soon as engine is cranked. I did timing 3 times using Volvo's cam and crankshaft alignment tools. Would you think I still have timing wrong and crankshaft sensor or camshaft sensor causing this?

If I'm right, crank sensor sends signals to ECU to release injection and signals fuel pump to run?

[zakmuh]

I'm just going through what we have checked so far and some other thoughts...

So far...:
Lifter pump (Low Pressure pump) in the tank is priming - so no need to check relays or wiring connections
Flow from lifter pump is steady and consistent up to HP pump - so fuel lines have no leaks
During priming, fuel would flow from HP to CR and also to fuel return lines - this is normal
When cranking fuel flows from CR and up to injectors but very low - no pressure
When cranking pressure sensor voltage remains at 0.51v - no pressure building up in CR
when cranking fuel returns line on HP pump side has same amount of fuel as to when priming - this is again normal and HP pump is not leaking
when cranking fuel returns lines connected to injectors having fuel coming through (not coming out of injectors) - this is normal

Basically fuel is coming to HP pump but no enough pressure there in order to inject into combustion chamber, hence no start. There are two things concern me:
1. When cranking fuel returns line on HP pump side has same amount of fuel as to when priming....I'd expect returning flow to reduce as SCV would allow half of the fuel to pistons to pressurise the outlet flow to CR?

2. Should I check if injectors are click to cranking? If the are not, then could ECU be cutting the signal cos all 5 of them cant be at fault

3. Immobiliser - leaving the widows and bonnet open and locking the car with key fob isn't triggering the alarm but red flashing light is on on the dashboard. Can I assume the immobiliser is not working? Could this me causing any starting issue?

I'd highly appreciate some advice to get it going again.

Thanks
________

[zakmuh]

Hi

I've done checks on SCV today and its in the video blow. 3 clips in there:

1st - Bulb connected to SCV connector
2nd - Live Data from scanner with bulb connected (same readings with SCV connected as well). This scanner has no option to adjust anything for this one. If there is please let me know
3rd - SCV removed out of the pump but connected to ECU. Then very low pressure air is blown into the valve to check its function



I'm not sure if the valve is working cos I could see air is leaking even after its closed?

Thanks

[zakmuh]

Morning all. Today's update



In this video I'm checking the SCV connected to the pump. SCV gets closed when ignition ON and very small amount of air getting to plunger side. Is this how SCV should work?

I'd highly appreciate if you could advise me on this

Thanks

[RickHaleParker]

Read the files

[zakmuh]

Thanks mate

Appreciated

[zakmuh]

Morning

Still not starting but I believe we have made some progress, ie scanner is reading better pressures this time and the way engine sounds is positive. I stopped cranking it after an hour of trying cos I was worried of burning the starter motor as I could see smokes coming out of it. Please see the video



Should I keep on cranking whole day till it starts?

I have loosed the EGR pipe that comes from the exhaust and haven't tightened the clamp yet.. This did to check the crankshaft sensor. So when I tried with used Easy Start, engine would run to the spray but loads and loads of blue smoke coming out of the EGR pipe. I dont get this blue smoke when cranking with key

Could I have flooded the pistons with diesel and thats why its not firing up?

[RickHaleParker]

Did you read this part in the pdf?

Caution! To prevent damage to the engine fuel injection pump, the tank pump must be activated for approximately 80 seconds by turning the ignition key to position 2.

It takes a long time to prime the fuel injection pump. #2 Diesel makes a decent lubricant. The fuel injection pump is designed to use the fuel as a lubricant.



Fun Fact: Bio-Diesel is a excellent lubricant. There been an idea to run Bio-Diesel through the crank case before using it as fuel. Never ending oil change. Longer engine life.