Vauxhall movano new engine non starter

[Chillman89]

Hey
I have recently replaced my vauxhall movano engine with a recon engine
Its a 2.5 dti g9u engine 2003
We believe we have done everything right timing and all after numerous checks
We did have to use everything from my old engine as the recon was just a tall bare engine.
She wont start on her own, she needs a spray of easy start then she runs fine and idles fine no lights on dash and gets up to temperature but still wont fire on her own.
But cranks fine
We pulled fuel through
Weve tested the glow plugs volts and they are continuously getting 10.7 v even with key out and after 30 mins of being off.
Not sure if thats normal
We get these faults when weve tried cranking:
Preheating relay circuit 1816
Heater plug circuit 1826
Airflow sensor circuit 1806
Fuel temperature sensor circuit 1805
Camshaft / engine speed sensor sync error 1808
The camshaft sensor was changed but still coming up
And only comes on when cranking for too long
Weve pulled fuel through
We are thinking wiring maybe corrosion in loom has damaged a wire but i wouldnt have a clue where to start
Does anyone have any info that could help
Thanks
Colin

[Bob225]

G9u is the Renault engine with cam belt - it take it you did the cam belt and tensioner ? did you use the correct locking tool and verify TDC ? it is possible to get them 90-180º out, I take it you turned the engine by hand 3-4 revolutions and made sure all the marks lined up including the pump if you didn't lock the cam it could be 3-5 teeth out

Don't throw parts at it, Camshaft / engine speed sensor sync is the giveaway if the timing is out, the engine will not start, the ecu will be confused, with the way these engines are wired they have a cascade failures

what was the reason for the engine swap ?

[Chillman89]

You are correct it is pretty much a renault engine
We used the tool but only for the cams as the crank was all aligned we did think fuel pump being out of alignment but were threw off due to it running fine.
However we checked the cams were still aligned but didnt check the fuel pump was.
Another thing we were thinking was the fuel pump side not the cog that runs the fuel pump but the fuel pump, does that need to be aligned to the cog as if i remember correctly it wud only go in 2 ways 180 either way.
We did turn the crank a fair few times before we put back on?
We changed due to cambelt snapped and destroyed nearly all valves and stripped bolts.
Could these other faults be coming up due to not being aligned
Thank you

[Bob225]

In a word yes, there al the same basic design 1.5, 1.9 and 2.0 and all suffer the same issues iirc the pump has a low side that pulls the fuel from the tank and the high side pushes it to the injectors at around 1600 psi

I would take a second look at the timing if that's ok do a leakdown of the injectors

http://www.matrasport.dk/Cars/Espace/va ... SYSTEM.pdf

[Chillman89]

Can you confirm if cylinder 1 is gearbox end do you know
We shall have another go at the timing
Thank you for your help ill keep you updated

[Bob225]

iirc you can get the crank out by 360º the marks will line up but the pump/cam sensor will be out 180º with out the crank lock

its been a while my memory is a little fuzzy

[Chillman89]

The only other thing that put us off the timing was when shes running she will run fine and idle fine and rev fine so surely there would be some sign if it was out other than just not firing?
The camshaft sensor only comes up after 5 seconds of cranking and the stop engine lightcomes on if started straight back up engine light stays on but if i wait 5 minutes it goes off on its own
Do the other codes not matter at this stage as 2 stay on regardless the preheating relay circuit and the fuel temp sensor circuit
Also what does iirc mean ?
And did you know about cylinder 1 at all or where i could find or how i find it as still not confident on answer?
Checking the timing monday and go from there just baffled
Thanks again

[Chillman89]

I don’t have a leak down tester but have done them. You remove the return fuel pipes off of the injectors and they each go into their own cup so you can see what fuel is flowing through them if any at all. We don’t necessarily need to do that we just need to find out if the ecu is cutting the fuel to the engine or not. If it’s the timing sync that’s the problem then the only way the ecu can prevent the engine from firing is by cutting the fuel but might be worth just confirming with matey that I’m correct. The only other way I can think of is the ecu stops the injectors from opening in which case we would have to do a leakdown test.

This is from a friend whos helping me

[Bob225]

I take it you cleared the codes from the engine with snapped cambelt ? are the injectors from the old engine ? is the vacuum pump all connected ?

[Chillman89]

No i didnt clear the old engine these codes are from when weve fitted the new engine
And yes injectors from old engine with new seals
I believe everything is connected correctly but will have another look and see

[Razor]

Was the van standing for a long time? How old is the fuel in it?

[Chillman89]

About 6 months standing and same with fuel
Thanks

[wine~o]

6 month old fuel will be stale, certainly wont help.

[Chillman89]

So empty and add new or mix new in
Would she run
Thanks

[wine~o]

So empty and add new or mix new in
Would she run
Thanks

I'd drain if possible and add new. However wait for Bob225 to log on and advise. He has much more knowledge of these Engines.

As an aside, my experience of Renault electrical systems/sensors isn't good. maybe just a dodgy sensor or an iffy connection