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Diesel estate - won't start.

Diesel - won't start - all experts baffled - NOT CPU or pump/fuel lines, injectors OK as are electrics. Is there a hidden sensor?

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First thing to check is to slacken the injector pipes and see if fuel is getting there when you crank the engine, if ok then it would be wise to check the timing belt has not broken , if ok then do a compression test of the engine. Has there been any work carried out prior to it not starting , regarding the timing belt or cylinder head?

Posted on Dec 11, 2009

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Posted on Jan 02, 2017

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Astra randomly cuts out at lights and engine May be sluggish,randomly code is P0093,FUEL RAIL SENSOR?


This diagnostic trouble code (DTC) is a generic powertrain code. It is considered generic because it applies to all makes and models of vehicles (1996-newer), although specific repair steps may be slightly different depending on the model.
When the computer sets this code it senses a large fuel leak in the high pressure section of the engine. The ECM in a diesel always monitors and controls the fuel pressure from the fuel injector pump to the injectors as long as the engine is running.
To set a code P0093 the ECM must sense a sudden large drop in fuel pressure within the system. This drop in fuel pressure can be internal, external or caused by a faulty sensor signal to the ECM.
When this happens, the ECM sets the code, goes into fail-safe mode which will suspend the fuel injector pump operation and allow one minute to pull over before it shuts the engine down. It will remain in fail-safe mode until the key is off.
The engine may run again but investigate the problem first. This problem will not correct itself or go away. The engine could shut down at any time or speed.
Unlike gasoline engines with fuel injection pressures of 30 to 50 PSI, diesel engine fuel pressure runs up in the Megapascal range, from 4,500 to 30,000 PSI. It takes very high fuel pressure to force fuel into the high compression cylinder of a diesel.
As you progress in diagnosing the problem be always mindful of the fuel pressure when the engine is running. It is ridiculously high! You have a code P0093 stating there is a large fuel leak in the system. Use caution when sticking your nose under the hood of a running engine with this code, or wrenching on the fuel system.
Symptoms Symptoms of a P0093 diagnostic trouble code may include:
  • Code set and malfunction indicator lamp illumination (check engine light)
  • Engine will enter fail-safe mode and shut down within one minute
  • Possible large loss of power above idle
Causes Potential causes for this DTC include:
  • Fuel injector failure
  • Fuel line common rail leak
  • Fuel pressure sensor malfunction
  • Fuel pump or lift pump failure
  • Fuel heater constantly on
  • Fuel temperature sensor failure
  • Leaks at any point in the high pressure circuit
  • Electrical connector corrosion or seating problems
  • Fuel pressure regulator malfunction
  • Fuel filter plugged dropping the fuel line volume
  • Injector pump leak
  • Fuel control actuator failure
  • Cascade overflow valve malfunction
  • Short in the electrical harness at the injectors or to the ECM
  • Fuel pressure limiting valve
  • ECM failure
Diagnostic Steps & Possible Solutions
  • Start with the engine off and doing a walkaround inspection for obvious fuel leaks between the fuel tank and the engine.
  • Lift the hood and check the oil and level. If the oil level has risen, smell the oil. If it is heavily contaminated by fuel, an injector most likely failed in the open position. Do not start the engine again until the oil and filter is changed.
  • Look under the hood for leaks. Start at the injector pump and follow the fuel lines to the fuel injector rail. Look at the injectors for signs of leaks.
  • Pull the electrical connector off the fuel pressure sensor and look for fuel in the connector. A failed sensor will allow fuel up through the sensor into the connector.
  • Check when you last changed the fuel filter. A plugged fuel filter will drop the volume enough to set the code.
  • Check all electrical connectors on the sensors and wiring harness to the injectors for missing insulation, corrosion or loose connections. If no obvious leaks have been found, go online and look up the TSBs (technical service bulletins) for your year and make vehicle. Diesels have no lack of problems as the TSBs will indicate.
Look for the code and associated repair procedures and probable causes. Chevy and Dodge reads like a book. The TSBs will include recalls on various items as well.
Look at your warranty. Most diesel engines have long warranty periods for various items. Many cover injectors for 7 years or better and 200,000 miles.
The dealer is the next step if no deficiencies are found. Checking the fuel pressure and the operation of the ECM takes special tools for a diagnosis.
Tip: Diesels outlast a normal gasoline powered engine when properly serviced. But they demand service at specific intervals to operate properly. There is no free lunch with these. Do not use any seals or gaskets that are not OEM. The pressures and temperatures call for the use of certain materials resistant to these temperatures and pressures.

Jul 12, 2016 | Opel Astra Cars & Trucks

1 Answer

Caterpillar troubleshooting


First thing to try with any diesel that won't start is to do a diesel system bleed. This one should be before the HP fuel rail type so start by bleeding the lift pump, then the fuel filters, then the main injector pump to lines to the injectors and lastly the injectors. Good luck.

Jun 07, 2017 | Ford Cars & Trucks

1 Answer

Ran out of diesel now vehicle won't start


This is not unusual on a diesel. What happens is there is air in the system. If this vehicle has an electric fuel pump loosen line where fuel enters injection pump then turn ignition key to the on position and watch for fuel to appear and then quickly tighten line before turning off key. Then try to start. If does not have electric fuel pump will need a second person. One will loosen line and watch while other cranks vehicle until you get fuel and tighten line before the other person releases ignition switch unless vehicle starts first. If that doesn't do the job do this where line hooks onto each injector. Probably will not have to do this to all injectors but could run rough until all the air gets out of everything. I have farmed with diesel tractor for 25 years and dad I drove the gm vehicles with the 5.7. You normally don't start a diesel without bleeding the air out of the lines although some will self bleed most won't. Hope this does the trick.

Jun 21, 2012 | 2004 GMC Sierra 2500

2 Answers

I have a c220cdi, it cranks but does not start. have changed all the seals and gaskets on the pumps and also the o-rings on the injectors. I have also fitted a non return valve to the fuel tank so the...


You obviously have a problem - before you waste anymore time or money - take it to a mechanic and get a correct diagnosis of the problem so it can be fixed properly.

Oct 30, 2017 | Mercedes-Benz C-Class Cars & Trucks

1 Answer

99 Dodge ram 2500 with cummins diesel stalled and won't restart. Changed fuel filter, and determined that there is fuel going to injector pump.


loosen one fuel line to one of the injectors, try to start the truck and look for the fuel to spray out of the line. it should spray rather hard if the injector pump is working right. if it just dribbles or trickles out you have a weak pump.

Jul 30, 2011 | 2000 Dodge Ram 3500

3 Answers

I have replaced the fuel pump twice in my 1993 nissan pickup. but it is doing the same thing with the 2nd fuel pump it did with the firsy. it ran like a top for 2 weeks then starting stalling out finally...


Pull the pump and check to see if the baffle in the fuel tank has come loose. Over time sometimes the baffle in the tank comes free and knocks against the pump causing it to short and damaging the pump itself. Unfortunately if that is the problem you will have to replace the tank. There is no way to remove the baffle or re-attach it.

May 31, 2011 | 1993 Nissan Pickup

1 Answer

1986 FORD F 350 DIESEL 6.9 REPLACED INJECTOR PUMP AND STILL DOSENT GET FUEL ALSO WHEN IT DOSE START THE IDLE IS AT 3000


check to see that your mechanical fuel pump is working on the lower right side of the engine. VERY problematic pump due to design and location. Have you replaced your fuel filter with the injector pump swap? cause you need to do that , its a must If your getting fuel to your injector pump you have to bleed the lines to each cylinder to bleed out the air in the system. If that all checks out then you need to set the timing to 8 deg using a timing light and a diesel injection pulse width adapter timing tool. purchase a haynes manuel for 6.9l/7.3l diesel engines to follow the correct procedure for setting timing to manufactures spec. You will have to disconnect sensor at certain times during the timing stage so make sure it is done right!
PS - I hope you marked a reference line on the pump to line up with the line on the housing cause that will get you close to start! good luck

Apr 07, 2010 | 1986 Ford F 350

5 Answers

Dodge cummins won't start, fuel reaching injector pump but no fuel coming out of injector pump.


You said you have fuel flowing from the inlet line of the injection pump? But not at the injector lines?

May 05, 2009 | 1999 Dodge Ram

1 Answer

97 Toyota camry


No.
Unfortunately diesel leaves a residue in the lines and on the injectors.
There is only one cure for this, take out the injectors and get them serviced and flush all the fuel lines out with clean gasoline.

Aug 05, 2008 | 1997 Toyota Camry

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