Back on with project Mangoo this weekend
First job on Sat was to refit the fuel tank and make some an-6 fuel lines up. Pretty boring and got a load of shite in my eyes as expected, did not take many pics. Only plus side was i bought some proper hose shears which cut the braided pipe like a hot knife through butter, which made the job acceptable to do.
Torques fitting to convert to an pipe, fits nice on oem sender outlet.
Made a short line from sender to tank. This was to make tank fitting and removal easy in the future. The an 90deg bend clips onto the tank which makes a neat job.
Pulled the oily ply lining ooutand binned. Floor is quite clean for a used van, did consider cutting an access hole for fuel sender but its dual skinned at that point so too much hassle.
Added the fuel pump wiring, put some tesco 99 in the tank and hotwired the fuel pump to leak check. No leaks so time to attempt fire first fire up.
Connected fuel pump wiring up, cracked ignition on and no fuel pump prime. Determined to attempt a start, hotwired the pump. Cranked over, no attempt to fire.
Stuck clip on for diagnostics and df061/062 present , i could smell fuel so knew the injectors were working, but no spark. Checked tdc was working as engine was seeing rpm.
At this point i was thinking poss immobiliser issues? Went and sat down and had a cuppa, looked through the s3000 pdf to see why no spark.
At this point i figured the diesel upc was set up different to suit compared to petrol. Megane rs upc is n4 and is basically identical looking to Kangoo n2, checked wiring and it all married up so went out and fitted it which was plug and play.
Cracked ignition on and fuel pump primes, winner. Goes to crank engine and it wont fecking crank! No fault codes stored so left it at that and done some more digging through the workshop manual.
Sunday morning i came out with a fresh head and plugged clip back on. Done a bit of digging through the upc live data and it says gearstick not in neutral. I knew exactly what the issue was, the sensor was not connected to the megane engine loom.
Plugged in the gear selector sensor and attempted to start. Fires straight up but misfiring, good to see it started but not good to see heavy misfire.
Start off by changing pencil coils to spare set. No change. Diagnostics, no faults stored, its either duff injectors or compression loss.
Fired the engine up and removed injector plugs one at a time. No change to misfire on cylinder 1 or cylinder 3, running on 2 cylinders!! I was a little worried about this as fearing ecu issues with 2 injectors not working. Pulled a spark plug on cylinder with non working injector to confirm - bone dry.
Next step i pulled fuel rail off and held it over blue paper towel whilst cranking the engine to fire the injectors. This proved only 2 injectors were working. To confirm faulty injectors or ecu fault, i changed the plugs from the working injectors to the non working ones, and they did not work so - diagnosis stuck injectors.
No spare 630cc injectors in stock, so give the non working injectors a gentle tap with the spanner, nothing to lose. This is an oldskool/pikey way of getting injectors to fire when stuck. More cranking to test and they started working after a couple of attempts.
Refitted fuel rail and attempts a start again with fingers crossed. Cranks/fires straight up on all 4 cylinders and settles down to 800rpm idle.
So loud with no exhaust system!!
With that milestone reached, let it warm up a bit and checked for leaks, no oil leaks, slight coolant leak which only required a jubilee clip nipping up. Refitted battery tray, upc covers etc. Deleted the gearbox selector switch, cut plug off and joined the wires together and hidden in the loom.
Done some flight checks, brakes work, clutch and gears work, drove it to the end of the drive and back, seemed ok in first gear. First time its moved under its own steam since purchase.
Coolant has gone a bit rusty as block had a bit of shite in it. Will run it through a few heat cycles and flush out.
So next job is to get it booked in for custom exhaust system, get some insurance on it, new windscreen as cracked, oil/coolant change, wipers etc then mot and road test, get a few miles on it to see if any issues and booked in for mapping.
Thanks for reading!!
