Hi,
I have a Boxer 320M, 2.5 non-turbo, (DJ5 engine), registered in 2001 on a Y plate. I have recently had the g/box rebuilt and a new LUK clutch fitted and have just completed the fitting of a new timing belt.
Prior to the fitting of said timing belt, the van started easy enough, but seemed to "miss" on the fourth stroke and a little puff of smoke was noticable on this stroke.
When I had the g/box overhauled, the mechanic, (when questioned about the above problem), said it could be one of the following:
1. Timing out
2. Glow plug/s bad
3. Injector/s need recalibrating
As I couldn't be certain of the milage and bought the van sold as seen with no warranty
from BCA, I had every intention of changing the belt to be on the safe side.
I purchased the Peter Russek workshop manual for this van, (also for the Relay and Ducato), as Haynes don't currently have one for this engine/van. Not the best of instruction, (seems to be biased towards the 1.9 unit), but I'm not an idiot and like to get my hands dirty, so the "basics" were all I needed.
I have now changed the belt, (try getting the right locking tools for the timing/injection. Nightmare
Give Laser tools a call and ask for the technical department and they will check Autodata for you and get the tools that match the OEM part numbers).
FINALLY (
), this is my problem. The van will now just turn over, eventually running the battery down in the process. It's "almost" there as far as starting is concerned, but it's as if there is a fuel starvation problem now and just fails to actually ignite. There is also a noticable "grey/brown" smoke from the exhaust as I turn it over.
Now, here's the worrying part. As anyone who owns one of these will know, this van has the Bosch fuel injection unit fitted, (well, mine does anyway). It has been noted by an assisstant that as the van is turned over, the fuel leaks, quite consierably, from somewhere near the top of the fuel pump, (that being the one fitted to the front of the engine, on the left hand side, just in front of the cam belt pulley). There is a large spring just underneath what is some kind of microswitch, and it looks like this is where the fuel is escaping from.
The only thing I did was to apply pressured steam to the engine to remove old oil whilst I had the timing belt off and also cleaned the fuel pump whilst I was at it.
Is there anything I might have knocked/affected with the steam, (I have cleaned it in this way prior to the belt change with no ill affects). Are there any problems I don't know about with the Bosch system that anyone could enlighten me to?
It really is frustrating me now and costing me a lot of money in down time. Any help/info/suggestions will be GREATLY received and appreciated. I'm stumped and I don't like to be defeated by simple mechanical devices.
Thanking you in advance in the hope of some much needed help,
onetruecharlatan