2.2 Diesel, non starter P0607 (6)

[sgould]

Looks much the same as mine.

[carrera]

Thanks for the replies

Some more messing around today, I thought I had found the problem, no fuse in position 27 which meant no volts to pin 16. I tested at the bulkhead connector H42-5 and saw 12v so reassembled everything, bled the diesel rail & fingers crossed

It coughed on the first revolutions but still has not started. I'm still getting P0607 (C) and  (F)

Not sure there is anything else I can do

I have found a s/h pump at a great price, but it's from a 2002-3 car, not a 2004-5 car

Do I only have to do a SPS programming on the chassis number, or does the immobilisor code need reading / changing too. 

[aerojon]

P0607 is internal ecu fault/failure other words ecu is toast..

[carrera]

Well, what do we have here (after a few weekends doing other stuff)

PSG16 ECU removed, without cutting any wires



Zoom in on the part numbers on the plastic cover



Remove the plastic cover and here's the guts. Looks like possibly silver wire, with a lot of clear grease/silicon type stuff for corrosion protection



Apparently it is usually a MOFSET transistor that fails, but a quick look by eye suggests there may be a broken wire here - I have not properly inspected yet. The other wires that I have seen failed before (on Polish sites generally) look OK



All linked for full resolution, in case you can see something I cannot

[carrera]

Well, a bit of an inspection and poke around and thewire I thought was broken was not, it was actually the earth

However, on the other side of the PCB, where the transistor is I have found a broken wire. I'll need to find how to repair this as I suspect a blob of solder may just melt and it's back to square 1

There's a you tube video with regrettable music here

https://www.youtube.com/watch?v=AqXxR74QBbA

This is the culprit - the micro screwdriver points to the break, which I suppose is causing the P0607 error

[carrera]

Just for the record, this is the MOSFET transistor fitted into these pumps

https://www.infineon.com/cms/en/product/power/mosfet/n-channel/irlr2905z/#

Not sure I need one as the fault appears to be broken wires, but I have ordered one in case I decide to replace it anyway.

£3.15 delivered, that's a lot cheaper than a new pump 

[sgould]

I’m wondering what caused the wire to break?  I suppose it can only be vibration. 

[carrera]

I have been mulling that over too.

It fits my theory that cranking the car over on a commercial battery charger in a vain effort to get the car started when there was air in the system "might" have resulted in a high wattage (volts x amps) situation, burning it out

In one thread (92 pages of it) someone suggested that a physical problem on the pump may cause a high current situation, which results in a failure of the MOSFET. But that's a P0606 error, rather than P0607, at least I think so

Remember, something similar is the cause of failed TCM modules on the 2002 cars....

[sgould]

Is the fuel pump an impeller pump or a reciprocal pump? 

I only have experience of larger water and sewage pump electrical control failure, usually due to blockage/jamming, or delivery valve failure, causing the pump to reverse when switched off. How's the fuel filter?  A high pressure diesel pump must have very close tolerances on all moving parts.

[carrera]

I would descrie it as a rotary pump - chain driven off the crank/camshaft with electonics controlling the injection timing / duration

Much more detail here

https://www.youtube.com/watch?v=vL5l11dmMmI

I agree on cleanliness, the filter was changed when I put her on the road after sorting the broken glowplug, so should be good. Bit of a shame that Saab decided to stick with suction only for diesel delivery, the tank is the same as a petrol, but the thing that goes in the big hole only performs the level sender function, no pumping of fuel

[carrera]

Time to make a little more progress on this.

I took the ECU to a local ECU repair guy. After putting it under the microscope he advised that there were 4 wires broken, and that it was not possible for him to repair it. So I have been waiting

On Friday I picked up a bare D223L engine, bare, including an injection pump that is

The plan is that I will swap the pump over. My original idea was to go through the process set out in WIS, which seems to be effectively a full strip down of the chain side of the engine. A fair bit of work.

As I put the engine away I noticed a cover plate which screamed at me to be removed. This is what I found.





I'm wondering if there is some way that the pump can be swapped over simply by removing the 4 bolts & the central bolt (after bending back the lock tabs) 

I suppose there will be a tensioner which may mess things up... anybody know ?

[carrera]

Right, I have been doing a little WIS reading now.

Seems I was on the right lines, but there are two chain tensioners, and it is necessary to remove the camshaft sprocket.

There's also a big no no don't try and unbolt the central bolt. It's factory set on a taper and provides the key element of injection pump timing

Does anyone know how essential the special tools are. I have usually managed with various other implements on other engines, but this looks like they may be more than just makig the job easier. The instruction below refers to some of them

Good opportunity to do the injector seals as well I suppose

[sgould]

I haven't done a diesel engine strip since the 1970's!!

But if you mark everything and take lots of photos, you should be OK.  Quick digital photos weren't available 50 years ago!!

[carrera]

Well, as is the usual case you were there before me. especially in this case as I have never done a diesel engine strip. Yet

Just had a quick look on ebay & managed to pick up a set of timing tools in a slightly damaged box for the grand total of ?19 delivered. That's cheaper than an oil change, whereas I was expecting 3 figures 

Just need to finish the black twin off first, but it looks like I'm all set, and i have an engine on the floor to practice with first 

[carrera]

These have arrived now

Very impressed... all the gear & no idea now