Request for Electrical advice after cylinder head replacemen

richardlb

Car: Zafira 2.2 (2001) 105,000 miles (Original owner, serviced annually)

History:
Car used every other weekend for 4 x 100 mile trips, rarely used in between.
19-Nov-2010: Service by local garage, including replacing spark plugs, car returned with uneven tickover
25-Nov-2010: Garage replace EGR valve (which had been causing fault code for over a year), car returned uneven tickover + slight hesitation.
15-Dec-2010: Garage replace top Lambda sensor because it was wildly fluctuating, and replace spark plugs again. car returned with slight misfire.
17-Dec-2010: Garage discover Coolant fluid filling a spark plug well. Car misfiring not used until return to garage on 5-Jan-2011.
(probably about 800 miles covered between Service on 19-Nov & 17-Dec)
5-Jan-2011: Cylinder Head removed due to misfire at beginning of the year, by local garage. Crack around one spark plug discovered.
(Suspect that Crack was caused by the garage over-tightening spark plug during service)
10-Jan-2011: Car moved to home address.
18-Feb-2011: Reconditioned Cylinder Head, kindly, fitted by AtomX.

After fitting cylinder head, car wouldn't start, Radiator fan operating, No Fuel to injector manifold.
Connectors rechecked, ECU disconnected & reconnected, still nothing.

Power applied to Fuel pump relay causes fuel pump to operate and feed fuel to manifold, so pump & relay both OK.
No Engine Management Light showing on dashboard, Ice warning light showing, radiator fan still running (Cold Engine)

Any Ideas ?

Is there a sequence to reconnecting ECU, battery etc when reconnecting after it has been disconnected for a long period ?
Does the Immobiliser need resetting ?
Are there any connectors which may have been omitted / incorrectly fitted or which are especially likely candidates ?

Does anyone have a wiring diagram or does anyone know which pins to check on the ECU connectors to check that power is getting to it ?

Thanks
Richard

ATOM_X

Re: Request for Electrical advice after cylinder head replac

you say that the fuel system is serviceable
when you power up (ignition on) does the fuel pump prime the system (fuel pressure)

astra22bertoneauto

Re: Request for Electrical advice after cylinder head replac

Check for 4 things:-

you have compression. no compression = problems! check timing/engine.
Take out plugs and sit them ontop of your engine (metal cover) with coil pack connected to them. Get someone to watch for spark as you turn over for 2 secs. No spark = no/bad earth.
Check fuel pressure by undoing the black knob on the inlet fuel rail. Push the valve (like a tyre valve) and fuel should shoot out. If you hear air then no fuel/pressure.
And most importantly! Check your ECU is working with OPCOM or Tech2 diagnostics. If your ECU is dead get another one but you will need the security code to program the VIN number, Transponders (KEYS) etc.

Hope this helps 😃

richardlb

Re: Request for Electrical advice after cylinder head replac

Hi,
Thanks for your replies,

Fuel does not prime from the ignition switch. Checked - NO fuel at fuel inlet Rail. (presumably no sparks either)
But according to the AA man does prime when the Fuel system relay is activated from an external power source, although I didn't check for myself, he could hear the petrol pump and fuel feeding through, which does imply that the ECU is not activating the petrol pump relay, but the fuel pump & relay do work.
AA man also bridged earth from the battery to earth on the rocker cover.

Have not yet checked for sparks, but assume it won't run without fuel, otherwise I will see you on my new Yacht !
I will check though, in case it shows up an earth fault.

Thanks

astra22bertoneauto

Re: Request for Electrical advice after cylinder head replac

My advice would be to just get an OPCOM plugged into it, see whats going on! Also there is a test function which will tell the ecu to activate the fuel pump relay. Whilst there check for any stored codes!

vocky

Re: Request for Electrical advice after cylinder head replac

is the crank sensor plugged in, also the knock sensor - both near the starter motor

also check the throttle body plug, this will stop the fuel pump from running if it's not connected correctly

richardlb

Re: Request for Electrical advice after cylinder head replac

Thanks,
I will check.

vocky

Re: Request for Electrical advice after cylinder head replac

throttle body would be the first to check, I've had that before :silent:

ATOM_X

Re: Request for Electrical advice after cylinder head replac

I made a three hour de-tour armed with a tech2

findings without tech2 fitted

Ignition On

Rad fan ON continuously
No imobiliser ilumination (dashboard)
No EML (dashboard)
No fuel pump priming
No TB initialising

findings with tech2 fitted

Ignition On
ALL ABOVE
No connention warning on tech2 (repeated connection process several times)

QUESTION
Would no imobiliser ilumination on dash indicate NO POWER TO ECU or NO SIGNAL FROM ECU?

astra22bertoneauto

Re: Request for Electrical advice after cylinder head replac

I would say ECU not responding! My opcom says the same thing if ignition is off. It would suggest no power to ecu and/or ecu faulty thus not responding.

Daz

Stupid question. But have u checked all the fuses. Had a similar issue on a corsa in work. And it was a fuse blown. Also check earth points under the battery tray/ chassis leg.

vocky

Re: Request for Electrical advice after cylinder head replac

I would check there is power going to the ecu before getting another, could be as Daz said above - blown fuse

heavenrock

Re: Request for Electrical advice after cylinder head replac

My advice is to just get a OP COM inserted into it to see whats going on! There is a test function, it will start telling the fuel pump relay ECU. Although the inspection of any stored code.

Daz

Theres no comms with the ecu with tech 2. So opcom aint goin to work either.

richardlb

Re: Request for Electrical advice after cylinder head replac

Thanks for everyone's help,
Eventually found the problem, it was no or a bad earth connection to the ECU, found using a dashboard light, i.e. a low wattage bulb, and a couple of bits of wire, have not yet found where the other end of the earth wire is / or is supposed to be attached, but added a nice thick wire direct to the battery terminal instead.
Now runs fine, no better than before the idiots serviced it, but still fine.
Drinks oil now though, which it has never done before, 2L in 1000 miles.