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Discussion Starter #1
We have a Boxer 1.9d 2001 panel van that is giving us a bit of a headache. The engine has been running as good as new untill a week ago. The van had been getting harder to start for two or three days with a little black smoke untill warmed up. We noticed that it was sounding a little rough, which turned out to be the air intake large round pipe which had come off the air inlet manifold (this not necessarily the cause of our problem).This was put right but during the day the engine took longer to start than usual. We gave her a fuel filter change, oil filter and oil change but difficult to start again. Drove the van for two or three miles and was fine. The next morning it wouldn't start so we changed the heater plugs, three of the old plugs were not heating up. The heater relay seems to be working ok. We have bled the new fuel filter, also the timing pump inlet. Diesel was being pumped past the solenoid (a new one) but it doesn't seem to be doing so now. We put a powerful battery on and tried to start the engine, which doesn't fire or smoke. We havn't looked at the injectors yet because we don't seem to be getting fuel past the solenoid. :confused:

Any ideas would be much appreciated.
 

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Discussion Starter #3
Many thanks for your reply.

We have no pressure readings and no diagnostics. The immobiliser was bypassed three or four years ago so that shouldn't be a problem. I have been told the battery charge light doesn't come on when the ignition is turned on and it has been doing this for a short while, on and off, but not affecting starting, driving etc (perhaps diesel dripping on something whilst bleeding the pump).

There doesn't seem to be a fuel safety cut-off on this model and it appears no in-line fuel pump if that helps.

Regards
 

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Discussion Starter #5
Thought we would give you an update on this problem which may help others.

The diesel solenoid was taken out and the hand bulb primer given a good squeeze which seemed to clear a blockage. Air was also in the exit side of the pump which could be heard bubling back through the pipe to the diesel filter as the solenoid was loosened. Other methods of clearing the timing pump, ie, hand priming and cranking the engine didn't work but I suspect we were the culprits in putting the air lock in the pump whilst working on the solenoid etc. However, whilst unscrewing the solenoid the air backtracked to the filter and the priming with the hand bulb when the solenoid was off obviously cleared any blockage. No metal filings or swarf is present and fuel runs out nice and clean. We took out the solenoid plunger and spring, put back the solenoid and and she fired up easily. We then put back the plunger and spring after testing on the positive wire which runs to it and again the engine runs sweetly.

The battery light still doesn't come on but I suspect thats another problem altogether, We will sort that out in the morning.

Many thanks for your help bettyswollocks
 

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Discussion Starter #7
It's worth changing the leak off pipes while you're there as these can let air back into the system causing crap starting
I thought other readers may like to know that we took advice on leak off pipe running back to the tank which we replaced, the engine seems to be running sweeter for it.

The ignition light not coming on problem was in fact the connection on the small cable on the alternator. :thumb:
 
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