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[platty]

Diesels do need lots of EGR for economy, so I'd be inclined to clean the egr (paint stripper).

I think I'm going to have the EGR pipework off and give it a spruce up and see if it has any effect - been meaning to do it for a while anyway.

[Turk]

What is the EGR valve and what can happen when it fails?

http://www.parkers.co.uk/advice/forum/topic.asp?TOPIC_ID=14421

[Turk]

The plot thickens.
Cleaned the EGR and checked it's operating as it should. No issues there. Replaced the original std chip to get things back to basics.  
Code 64 still showing so gave it another dose of Diesel Magic with a drop of Kent Fuel Guard II.
Code 64 now gone [size=10][size=9](phew!)  [/size][/size] and Code 82 (Sensor injector start incorrect RPM-Signal) has now appeared for the 1st time, hence the title of this thread...but no code showing back then, just had a feeling, going on the symptoms (or maybe wishfull thinking...anything but the dreaded 64).

Just checked the fault codes and 82 still showing for the sensor injector...but 96 (EGR) is back again  :-?
I've develop a twitch when anyone mentions Fault Codes.  

Anyone know what socket/tool is required to remove the sensor injector ?
It's a deep 27mm socket, but needs to have a thin wall, as an impact socket is too thick to get down onto the sensor.
I would need to grind down and cut a section out of the side to allow the wires and plug to pass through if I have to use an impact socket.

[Turk]

...and this evenings (un)lucky numbers are 64, 82 and 96. (Oh don't stop there, I'm sure you could find a few more to add !!)

Yep, they're back again. All three this time.
I know how he feels: http://www.youtube.com/watch?v=mmQMYMcY6nI

I know the EGR is right, I cleaned and checked it last night.
Hopefully the injector sensor(82) is sending wrong signals and upsetting the others. Just need to find/make a socket to get it off.  

[Seth]

You need a 'window-type' deep hexagon socket dear Sospanite!

Most motor factors sell them, although I've got one here if you want a lend. As it's presently unused, you're welcome to take it on it's maiden voyage if you wish!

[TheBoy]

Its called a Diesel Injector socket.  Cheap ones break - Omegatoy did 2 of mine - so I got some better quality Draper Expert ones.

But you may be able to repair the cable - so check cable for damage

[Turk]

Its called a Diesel Injector socket.  Cheap ones break - Omegatoy did 2 of mine - so I got some better quality Draper Expert ones.

But you may be able to repair the cable - so check cable for damage

Got this en-route:
http://www.ccw-tools.com/product.asp?strPageHistory=home&numSearchStartRecord=0&P_ID=3315&CAT_ID=0&numRecordPosition=1


TB, Yes....Omegatoy did mention he'd destroyed two of yours  

[Turk]

Apart from the wiring, what faults can they develop and what rpm range does it regulate ?
From what I gather it's start-up and lower rpm range, but up to what point ?

Lord Maesteg, thanks for the offer of the socket. The one I've ordered today is now at Luton depot and should be delivered to me at work tomorrow, but it's good to know there's one available locally if I do an Omegatoy and start destroying them.
 

[Omegatoy]

Apart from the wiring, what faults can they develop and what rpm range does it regulate ?
From what I gather it's start-up and lower rpm range, but up to what point ?

Lord Maesteg, thanks for the offer of the socket. The one I've ordered today is now at Luton depot and should be delivered to me at work tomorrow, but it's good to know there's one available locally if I do an Omegatoy and start destroying them.
 

LOLOL The first one i took out of an omega td was a practice run at the scrappie, went there armed with a good quality socket and a 30 inch snapon breaker bar, got inlet off, put socket and breaker bar on injector and nothing it would not shift at all, poured some oil in the well gave it a few mins to soak in, tried breaker bar routine again and i may as well have tried to push a house over!!! hunted round found a nice piece of scaffold baR ABOUT 5 feet long, placed it over breaker bar and pushed and pushed and pushed as hard as i could 2 mins later there was a horrendously loud crack and i knew i had broken me breaker bar!! but no it was the sound of the injector letting go on the threads!!

success!!

 i thought!!!

nope had to use the scaffold bar and walk around the car whilst unscrewing the injector to the accomanying sounds of threads being ripped apart, not a nice sound at all,
the injector finally gave up with about 2 threads to go an i could then undo it wit just the breaker bar on, thinkiung it would be ruined i insected the threads carefully on the injector, perfect!!!!! however the head it came off the threads didnt look to good(aluminium, )

So when i did the first road car i poured loads of parafin mixed with engine oil into the well and left it to soak over night just in case, came out beautifuuly smooth and was replaced with the scrapyard one with no worries!!
moral be careful when removin it mate!!!!

[Seth]

Apart from the wiring, what faults can they develop and what rpm range does it regulate ?
From what I gather it's start-up and lower rpm range, but up to what point ?

Lord Maesteg, thanks for the offer of the socket. The one I've ordered today is now at Luton depot and should be delivered to me at work tomorrow, but it's good to know there's one available locally if I do an Omegatoy and start destroying them.
 

When my No.4 injector played-up, the car felt like it was permanently trying to pull another tractor uphill!

[Turk]

I've put the "Slugtune" chip back in for now, until I get this sorted. (Actually that's a bit un-fair on the standard chip as it's not that bad in standard VX mode, but the full power chip does make a big difference.)
At the moment it pulls fine, from 1000rpm in 5th,  right up to red line.  Needs 5-6 seconds of cranking when cold and about 2 seconds when warm. Un-even at idle but raising revs to around 1000rpm smoothes that out. Slightly un-even when on the move until 2500rpm and above.  

Just been over my mates garage to give the injector a soaking with Silkopen in readyness for tomorrow evenings removal ceremony.

[Seth]

Good luck tomorrow evening brother!

[Turk]

Cheers matey.
After what Omegatoy said about it being seized solid, I thought it best to do some preparation.
Silkopen graphite penetrating spray is good stuff.  This should be the ultimate test.

[Omegatoy]

Cheers matey.
After what Omegatoy said about it being seized solid, I thought it best to do some preparation.
Silkopen graphite penetrating spray is good stuff.  This should be the ultimate test.

certainly will be!! injectors have an extremely fine thread for strength and close tolerances, i found it best to crack the seal more oil then wind it back in and keep doing it up and undoing it a bit more and so on, having said that the boys came out easy!!!! maybe cos the car was in constant use? whereas the scrappie one had sat for a year or so?
anyway good luck and dont forget to have new injector seal ready!!!

[Turk]

Now I'm baffled  :-?
This... http://www.ccw-tools.com/product.asp?strPageHistory=home&numSearchStartRecord=0&P_ID=3315&CAT_ID=0&numRecordPosition=1  will not go down onto the injector.
The walls are 5mm thick and the corners are 3mm. It will not go down into the injector recess.
Could someone please measure one that they have actually used and know for certain the size of the socket and thickness of the wall ?