I recently had a cam belt go on a 2002 1.8 cdti 115ps. I took off the head and replaced two valves and rebuilt the engine. I can't get the engine to start. I have sprayed easy start into the air intake and the engine started so I am guessing that the engine is ok, I suspect the electronic injectors are not delivering fuel into the cylinders. Is this something that needs re-setting electronically? Could the ECU be in some sort of failure mode following the cambelt failure? Any ideas appreciated!

Its possible that the ECU is done for, however have you done an injector test?

Thanks for that,

I haven't done a leak off test as I don't have the equipement, but don't understand why the ECU would be damaged when the cambelt failed.

The ECU is delicate, if there was any electrical troubles as a result of the CAM belt its possible. You dont need professional equipment to do a standard injector test, I have seen someone on this forum remove the injectors, and place them inside a bottle, sealing the bottle up with tape (leaving all four injectors dangling inside a bottle) and then they try to start the car. The fuel enters the bottles through the injector, and you should see a reasonable amount of fuel in each (all should be relatively equal) if after a few turnovers you have fuel all over the place then its a potential injector problem.

Thanks for that, I will have a go and let you know how we get on.

Hi,

The diagnostics indicated a catastrophic failure of the fuel pump, I have contacted a diesel injection specialist who has asked me to bring in the injectors so they can test them. They said the pump is likely to be OK but the ECU may have lost contact with them, also it is very easy to contaminated the injectors despite covering each one and all the broken connections with fingers from poly gloves.

So we are first cleaning and testing the injectors to make sure they haven't become contaminated during the engine rebuild and then remapping the engine management system to get it talking to itself.

I'll keep you posted...............

Looking forward to a positive and inexpensive outcome!

if injectors are touched they need the knock sensor value reset...or so my IDS says

^{After cleaning and re-setting the injectors we had the car running but popping through the inlet manifold. Finally got to the bottom of the problem........ The two new valves I had installed left the gap too tight on the tappets causing the valves to pass. I have ordered two new shims to re-set the clearances - a factory order - so we should be finally running again later in the week.}

Sounds like a positive outcome, whats the cost so far to repair?

^{Costs for the job worked out at:}

^{Secondhand Cam Cover £14.00 *}

^{Head Gasket Set £37.75*}

^{Cam Belt Kit £44.98 *}

^{Inlet & Exhaust Valves £19.92 *}

^{Stretch Bolts £24.50 *}

^{Fuel Filter, Injector Clean and Re-Programme £149.82}

^{2 Shims £16.78}

^{Total £307.75}

^{-----Original Message-----}

Given the work involved and what would have been the cost for the injectors, thats not a bad price!