Hi Everyone, Sorry for the long message, wanted to give as much info as poss. Please help if you can.

I have a Trajet 2.0 CRDI Automatic. I’ve had it since it was 6 months old. Mileage was 6000 when I bought it, now has 61000 on the clock. It had been serviced by a local Hyundai dealer for its first 3 services, since then I have changed the oil etc myself.

At 61000, I decided to replace the timing belt, officially due at 60k. This went well and the car worked fine for the following 3 weeks being used at least once every two days. As part of the timing belt service, I also changed the fuel filter, but only after the problem below started. I don’t have any warning lights on the dash reporting problems and when the engine is running, it’s smooth, powerful, responsive, no smoke, no knocking, not loosing oil or water, runs perfectly.

It started taking a little longer to fire-up, 6 or 7 seconds of turn over before it starts. Over the next 2 days, this got worse and worse, taking longer and longer each time until it wouldn’t start at all.

The AA where duly called out, and the mechanic tested the injectors and said there was no current going to them from the computer. He then tested the camshaft sensor and said it was fine. He sprayed a small amount of “EasyStart” in the turbo air pipe and the engine fired up straight away. While it was running. he tested the injectors again and said they where now getting a current. He claimed it must be the crankshaft sensor not reporting to the computer and so the computer wasn’t opening the injectors, but he didn’t know where it was. Later, after I spent 2 hours looking for the crankshaft sensor but not finding it, we where told by 2 mechanics that not all diesels have a crankshaft sensor!

1st Question,
Does this car have a crankshaft sensor? And if so, where can I find it?

One mechanic told me that injectors should be changed as often as spark plugs, another mechanic told me they only need changing (rarely) if they stop working.

2nd Question,
How often should the injectors need replacing?

I then contacted my Hyundai dealer and explained the symptoms. Immediately, he announced it was a common problem and is caused by the fuel pump not building up enough pressure to push the fuel through the injectors, or it was the injectors themselves need replacing. We tried testing the pressure on the pump but couldn’t get a reliable reading so I did some research and found a washer replacement kit for the high pressure diesel pump for just £15. I serviced the pump and put it back on, and after bleeding the diesel, and charging the battery, the car started!! Hooray (I thought)

The car worked for 2 days, then slowly took longer and longer to turn over and start till it wont start at all. A small quirt of “EasyStart” gets it going, but even after a long journey, warm engine, stop it and it wont start again even straight away.

The battery is original, but seems to have plenty of power. Engine turns over fast enough. Volt meter reports 12v and 80+ ah.

I have now spoken to lots of people and had various suggestions. Here are some, please give your opinions and suggestions.

1, Could be sucking air, creating airlocks in the fuel line?
If so, know of any common locations for this? If I bleed the injectors, it’s still 50/50 if the car starts.

2, Could be not enough power in battery for computer? (I think there is.)

3, Injectors need replacing?
(When the car is running, it is smooth and powerful, not miss firing or underpowered. If I had just one infector faulty, I would know by just listening would I?)

4, Blockage in the fuel line? (wouldn’t run nicely when started)
5, Main computer needs replacing? (I don’t think so)

Today, I purchased an ELM327 to have a look at the computer. Loaded up the software on a laptop and plugged in the car. The software runs and see’s the car, but the only information I can get out of the car is the error logs.

Question,
Is the Trajet 2 ltr Diesel Auto (UK model) 2003 model CBDII compliant?

I can see one error only, and that is P0720. This may be my doing, I removed the gearbox speed sensor on advice that it may have been the crankshaft sensor. I cannot see how I could have put it back wrong as its simply one bolt that holds it on. There is a lot of diesel spilt on the engine and I hope its just dirty. I will look at this again when I’ve sorted the starting issue.

Any advice would be very much appreciated. I will update you all soon as I find more out. I know that if I take it to a garage, they will find something silly wrong and charge me the earth for the pleasure. I would love to resolve this myself.

Cheers,

This post has been edited by Kimpton: Sep 25 2009, 06:12 PM

Try something for me. (IMG:style_emoticons/default/grin.gif)

Try a set of jump leads and using another car/vehicle try jump starting the trajet,its possible the battery voltage drops below the critical voltage trying to start it .

Initial battery voltage should be nearer 12.5v and not drop below 12v but usually 11.5v will start.

This simple test using the jump leads will rule out the battery being a problem.

If the above does not fix it then I think its pressure related,to test it you will need a diagnostic tester/reader to measure the fuel pressure or use a multi meter on the sensor on the injector rail.you are getting into an area where you realy need to know what you are doing/looking for.Easy start is really only a one off get you going thing its not worth using all the time go easy on it .

Let us know what happens (IMG:style_emoticons/default/thumbsup.gif)

Hi Weeboad,

Many thanks for your suggestions. We too had suspected the battery and have tried jump starting it many times. I have tried with a small Rover 100, the AA man tried with his van, my dad tried with his Jaguar XJ V8 & his VW transit van, and we have a powerful battery charger. We even took the battery off the Jag, none of them get the car started.

I haven’t been using the "EasyStart" often. I understand it can cause bigger problems, we have only used it to get the vehicle started in order to take it too and from a garage to work on it. Maybe 4 times over the past 3 weeks.

I will go back and check pressures again. What pressures do you think I might not be getting? Fuel or cylinder compression?

The Hyundai garage told me this was a very common fault with the Trajet, but I can't find anyone else in the forum with similar issues, was he just touting for work to make me think he knows what he’s doing?

Thanks,

How are you measuring it? what are you using ?

I dont think its compression(engine)and to be honest I cant see the injectors being the problem ,to have them all do it together is strange so im kinda thinking more the pump but we need to test the pressure first, no point in guessing

My father is a retired mechanic. He has a gauge that we attached to the rail.

When we first tested it, when cranking the engine over, we where getting 200psi. I removed the pump and replaced all the washers inside. We had been told that we should be getting 400psi. After putting it back on, and bleeding the pipes, the car started, and did so many times for the next 2 days so we didn't check it again.

I will test it again and let you know what we are getting now. Do you know what pressure it's meant to get to?

Cheers,

thats way too low mate ??

over 1,000 bar/15,000 psi is nearer the mark

Oh ?!?!

WOW 15,000psi !! Are you sure, do you mean 1500psi?

Our reading was when the engine is being turned over by the starter, not when the engine is firing.

This post has been edited by Kimpton: Sep 26 2009, 04:08 PM

These figures are generic but are correct.

Thanks for the information. I'm shocked at the pressures involved. I knew they where high, but I didn’t think they would be as high as that. I will need a bigger gauge, lol.

Many have suggested that the pump is the most likely cause, but I don't understand how the engine runs fine once started. Wouldn't the lack of pressure cause the engine to run lumpy and under powered?

Could I be getting an air lock from somewhere?

I will get the pump tested in a garage.

What about the mystery "crankshaft sensor"? Does my engine have one?

Cheers for the support.

...we where told by 2 mechanics that not all diesels have a crankshaft sensor!

1st Question,
Does this car have a crankshaft sensor? And if so, where can I find it?
I'd be amazed if it hasn't got one, it's likely to be right next to the crankshaft pulley (the quadrant where the cambelt doesn't pass around the pulley). Did you look there?
Problems with this would usually show up a diagnostic code.


One mechanic told me that injectors should be changed as often as spark plugs, another mechanic told me they only need changing (rarely) if they stop working.
Modern spark plugs can go 100,000 miles so perhaps both mechanics are correct.
2nd Question,
How often should the injectors need replacing?
rarely

Sorry this isn't much help but I think you are on the right track looking at the fuel pressure.

This post has been edited by andycarter: Sep 28 2009, 07:03 AM

Hi Everyone,

Well, finally solved this issue. Here’s a rough breakdown of what I had done and what was causing the problem. Many thanks for everyones suggestions, I enjoyed the challenge of solving this and have since learnt a great deal about my engine.

As posted earlier, I have a Trajet CRDi 2.0 Automatic on a UK 2003 plate. It has done just over 60k and prior to these issues, have had 6 years of trouble free driving.

After I had removed the diesel pump, dismantled it, and replaced all the seals, this only solved the problem for a day or two. I finally found the crankshaft sensor at the back of the engine at the junction of the engine and gearbox. I had to jack the car up in order to get to it. I didn’t remove it, but followed the cable back to a plug, which I could then test the ohms. This seemed ok, so I was at a loss once again.

I decided I needed some hands-on advice, so found a local diesel specialist who came by and connected his Bosch diagnostics machine/laptop to the cars computer. This reported 4 errors, but once cleared, these didn’t return.

He then attached some bottles to the injector feedback pipes and found that injector No.4 was blocked! He charged me £60 cash for all this.

He was able to source me a reconditioned injector for £180 cash the next day. A new injector was going to cost me £250 + VAT. I fitted the injector myself and the car started first time!

I am pleased with the result, still worked out cheaper than taking it to Hyundai, but took me a month or so to resolve. Thankfully I had the wife’s car to use in the meantime.

Here’s a breakdown of my expenses:

£40 for an ELM327 Cable off eBay
£5 for a can of “Easy Start”
£15 for a seal set for the diesel pump
£5 for a can of Break & Clutch cleaner for cleaning the pump components
£60 for the diagnosis
£180 for a reconditioned injector

Total : £305 cash (and about 25 hours of my time and stress, lol)

My recommendation to anyone having a similar problem is to get a diesel specialist to visit your home and test the car. As you can see from all the previous posts, this issue can be caused by a multitude of components and without the correct equipment I found it couldn’t be solved by trial and error.

I have since found all the shop manuals for this engine, D4EA, I have uploaded a zipped file of this manual to my website, you can download it from:

http://www.kimptoncomputers.co.uk/downloads/trajet.html

Once again, many thanks to everyone who suggested items to check out. I hope this information helps someone else in the future.

All the best,

Kimpton

By the way, the sensor is at the back of the engine, near the bottom, and is picking up from the fly wheel. I found it after looking in the Shop Manual. I had to jack the car up to get to it.

Thanks for the advice anyhow.

Thanks for posting the manual!!!

I see a turbo exposed in the manual.
I drive a Trajet CRDI but could never locate a turbo charger. Are there two versions of the Diesel engine for the Trajet? CRDT (T for Turbo?) and CRDI (without turbo)?
Sparks