Renault Master 2.2 DCi 2002 - Non start, code DF195 - Fixed #
Posted by George Georgiou on March 4, 2013, 7:45 pm
Year of Manufacture *: 2002 Engine Size and Code *: 2.2 ( Optional ) Scanner Used: Launch ( Optional) Fault Codes: DF195 camshaft coherence,no signal or timing fault
Customer bought as non runner and replaced oil pump in sump due to oil pressure problems and failed turbo (broken up impeller and shaft). Fixed problems and van run well for more than a month. Only recently on a drive an engine noise heard and van driven home where it was switched off and immediately could not be restarted.
Non start on inspection, weird problem in so much as I can scan the fuel pressure sensor and watch it build 350 to 420 Bar pressure on extended crank with battery support and yet there is no fuel in the rail apart from a dribble. Also Picoscope shows very healthy trace i.e. 0.5 volt on switch on with build up of pressure to about 2 volts as I crank and then gradual climb down with final switch off to 0V with ignition off.
Also only code scan evident after every clear and crank session is Launch code " DF195 Coherence between camshaft sensor, no camshaft signal or problem on the timing belt tension or timing setting"
Removed camshaft sensor which is fitted just in front of the fuel pump and found substantial metallic debris attached to magnet, cleaned put back, scoped with Pico and found very good timing signal.
My conclusion is that something has failed possibly due to turbo remains left in engine after rebuild causing either timing chain fault or fuel pump fault which needs a strip down to investigate.
However my question is? How is it possible to be reading fuel pressure from the sensor and yet there is no fuel in the rail? There was no fuel in the main feed pipe to the rail and also non on a cracked open injector pipe from the rail and yet I was getting correct pressure readings every time I crank the engine???
Hi george did you crack open the feed pipe to the rail while the engine was cranked? if yes did you scope or remove the fuel pressure control valve to check it's condition?
Forgot to mention that this vehicle has an electric lift pump which appears to be priming OK.
Its pretty obvious from the test of opening the fuel rail pipe to an injector and cranking the engine that the fuel pump is dead as no pressure or flow is present but why does the pressure sensor behave as though the pump is doing its job even with the pipe to the injector left open?
Its not imagined reading both Pico and Launch were showing side by side results of correct cranking pressure.The fuel rail only has the fuel pressure sensor fitted and the pump has a regulator solenoid which again was shown to be pulsed by the ECU during cranking.
>>> its pretty obvious from the test of opening the fuel rail pipe to an injector and cranking the engine that the fuel pump is dead as no pressure or flow is present but why does the pressure sensor behave as though the pump is doing its job even with the pipe to the injector left open? <<<
I think there is a valve incorporated rail port to prevent uncontrolled pressure loss in case of pipe failing.
Do you still get a pressure reading when pipe TO the rail is removed ? Please remember to take relevant safety precautions of course.
Aidan
Fixed #
Posted by George Georgiou on March 10, 2013, 8:50 pm, in reply to "Re: Renault Master 2.2 DCI - NON START" Edited by board administrator March 15, 2013, 10:50 am
The outcome was 2 stripped cogs connecting the fuel pump cog to the crankshaft drive cog. These are sealed by the front cover and fed by an oil spray tube and its suspected were damaged due to oil starvation when the oil pump failed inside the sump which also took out the turbo.
So pump drive was compromised and this explains the DF195 fault code. However still cannot understand how fuel pressure readings were obtained from an empty fuel rail???
on March 4, 2013, 9:23 pm, in reply to "