1995 SRi X20XEV won't start

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Joner1983
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1995 SRi X20XEV won't start

Post by Joner1983 »

Hi all
As well as my '90 SRi I posted about earlier, I am also having issues with my '95 SRi Ecotec. This one does turn over but doesn't fire. No eml light flashes up. I couldn't here the fuel pump relay clicking so I swapped it for an old one I had lying around and that didn't click either (maybe they are both faulty) I sprayed some easy start into the air intake and tried starting but it just burnt the spray and went back to just turning over. Is there a way of testing the relay theory without having to get a new one posted out?

Many thanks in advance :thumb
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
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Robsey
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Re: 1995 SRi X20XEV won't start

Post by Robsey »

The relay has quite a few pins on it.
To power the injectors and fuel pump, then you need to run a link from the fat red wire, to both of the blue / red wires.

One blue / red is for the injectors,
The other blue / red is for the fuel pump.

I am assuming that it is either a faulty pump, or connector.
Both are located under the rear seat bench, below a plastic cover that you can peel out, to reveal the pump, pipework and two pin power connector.
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Robsey
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Re: 1995 SRi X20XEV won't start

Post by Robsey »

Simple things first.

How is fuse 11?
The pump is powered through fuse 11.
Joner1983
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Location: Swindon

Re: 1995 SRi X20XEV won't start

Post by Joner1983 »

Fuse 11 looks ok. I lifted the back bench expecting to find the access to the fuel pump but this one doesn't have it. Is it possible this model has an out of tank pump?
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
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Robsey
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Location: East Manchester

Re: 1995 SRi X20XEV won't start

Post by Robsey »

I would not have thought so, no.
Joner1983
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Posts: 135
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Location: Swindon

Re: 1995 SRi X20XEV won't start

Post by Joner1983 »

Sorry, the carpet cut was so neat I couldn't see the flap! Found it now. I'll whip out the fuel pump and have a look at it, cheers
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
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Robsey
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Location: East Manchester

Re: 1995 SRi X20XEV won't start

Post by Robsey »

You could short the relay as described and see if you can hear the pump running, now that the seat bench and carpet are no longer there to act as sound proofing.

Although, because it is in the tank, the pump could still be very hard to hear.

If you take the pump out, be careful of fuel vapour and sparks!!
Joner1983
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Posts: 135
Joined: Thu Jun 16, 2011 10:50 pm
Location: Swindon

Re: 1995 SRi X20XEV won't start

Post by Joner1983 »

I have no idea if this is a correct method of testing but today I unplugged the lead at the pump and put my multimeter probes into the plug with the ignition on and I only got 4.48v. Does this mean anything?
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
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Robsey
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Location: East Manchester

Re: 1995 SRi X20XEV won't start

Post by Robsey »

If you want correct pump voltage, then the engine needs to turn over at, or above a certain rpm.

The engine will not properly energise the pump and ignition system below that rpm threshold.
Joner1983
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Posts: 135
Joined: Thu Jun 16, 2011 10:50 pm
Location: Swindon

Re: 1995 SRi X20XEV won't start

Post by Joner1983 »

Ah, ok. I've got a spare battery so I plan to get the pump out and hook up a couple of leads directly from the spare battery to the pump to see if it runs. Hopefully this should tell me for sure if it's had it....
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
Joner1983
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Posts: 135
Joined: Thu Jun 16, 2011 10:50 pm
Location: Swindon

Re: 1995 SRi X20XEV won't start

Post by Joner1983 »

So I've got the pump out, I've hooked up a cable from a spare battery to the terminals on the pump and it's dead. In the How2 it mentions something about the fuel filter being at the bottom of the pump.

Image

Maybe a stupid question but where is it?
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
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Robsey
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Location: East Manchester

Re: 1995 SRi X20XEV won't start

Post by Robsey »

It should be a plastic mesh like filter inside the bottom of the white plastic body.

The farthest point from the pump.
Joner1983
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Posts: 135
Joined: Thu Jun 16, 2011 10:50 pm
Location: Swindon

Re: 1995 SRi X20XEV won't start

Post by Joner1983 »

New pump in but just as I'm about to start her up I notice a fuel leak under the bonnet....

Can anyone tell me what this hose is called and where I can find a replacement:

Image
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
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ilovedmymantas
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Joined: Sat Jan 12, 2013 2:54 am

Re: 1995 SRi X20XEV won't start

Post by ilovedmymantas »

That hose is the fuel feed pipe.

The part no. is 90344377 (rhd)

Might be worth trying a Vauxhall dealer, even the European sites I search have so far drawn a blank :(
" It's not rust. It's age-related patina " ;)

1980 vauxhall cavalier MK1 1.6L, 1982 opel manta berlinetta 1.8s, 1985 opel manta 2.0 gte, 1990 cavalier 2.0 gl ,1994 cavalier sri x20xev

-1995 cdx x20xev

---------------
Matt
Joner1983
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Posts: 135
Joined: Thu Jun 16, 2011 10:50 pm
Location: Swindon

Re: 1995 SRi X20XEV won't start

Post by Joner1983 »

Cheers for that, I'll get looking. In the meantime I'll just horse a load of duck tape around the leak, as it's only small, so I can start it up and check my new fuel pump is good :thumb
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
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Robsey
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Posts: 10619
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Location: East Manchester

Re: 1995 SRi X20XEV won't start

Post by Robsey »

This shouldn't be a bank buster.

https://www.online-parts.co.uk/vauxhall ... _Hose.html
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ilovedmymantas
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Re: 1995 SRi X20XEV won't start

Post by ilovedmymantas »

in my defence, I moved on when the picture didn't match the part number :roll: :oops:
" It's not rust. It's age-related patina " ;)

1980 vauxhall cavalier MK1 1.6L, 1982 opel manta berlinetta 1.8s, 1985 opel manta 2.0 gte, 1990 cavalier 2.0 gl ,1994 cavalier sri x20xev

-1995 cdx x20xev

---------------
Matt
Joner1983
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Posts: 135
Joined: Thu Jun 16, 2011 10:50 pm
Location: Swindon

Re: 1995 SRi X20XEV won't start

Post by Joner1983 »

So new fuel pump is in, fuel feed hose replaced, replaced another perished hose underneath and the car starts and runs with the help of some cold start. Problem I'm having now is I can get it to start and run but if I try and take it round the block or leave it idling for a while, eventually it will stall and then it struggles to start. When it stalls the EML light comes on. It also comes on if it starts idling a bit rough but goes out when it starts idling normally again. Any suggestions how I can get her running sweet? I was hoping to get it MOTd soon and back on the road.

Cheers
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
User avatar
Robsey
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Posts: 10619
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: 1995 SRi X20XEV won't start

Post by Robsey »

Try doing the paper-clip test.
The code that is flashed out should tell you what is upsetting the engine ecu.

viewtopic.php?f=70&t=16896&p=171504#p171504

By the way, your car does not have an octane plug, so you will not find one in your car.
Joner1983
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Posts: 135
Joined: Thu Jun 16, 2011 10:50 pm
Location: Swindon

Re: 1995 SRi X20XEV won't start

Post by Joner1983 »

Ok I've got:

13 - Oxygen sensor - open circuit
92 - Camshaft Sensor Fault

Pretty sure I changed Cam Sensor several years ago. Would that be an old fault or is it likely to have gone since then?
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
User avatar
Robsey
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Location: East Manchester

Re: 1995 SRi X20XEV won't start

Post by Robsey »

It will be within the last 25 starts of the engine, or since you last disconnected the battery.

Chances are, you have a dirty or loose connector, pin or damaged wiring to one of those two sensors.

Unplug, clean and dry, the sensors and their connectors,
then take the car for another test drive.

And check all your earths, just to be on the safe side.
Joner1983
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Posts: 135
Joined: Thu Jun 16, 2011 10:50 pm
Location: Swindon

Re: 1995 SRi X20XEV won't start

Post by Joner1983 »

Awesome Robsey, I'll give that a try tomorrow :thumb
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
User avatar
ilovedmymantas
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Posts: 1202
Joined: Sat Jan 12, 2013 2:54 am

Re: 1995 SRi X20XEV won't start

Post by ilovedmymantas »

Robsey wrote:It will be within the last 25 starts of the engine, or since you last disconnected the battery.

Chances are, you have a dirty or loose connector, pin or damaged wiring to one of those two sensors.

Unplug, clean and dry, the sensors and their connectors,
then take the car for another test drive.

And check all your earths, just to be on the safe side.
Agreed.
Both these faults are a common recurrence with this engine, not forgetting the idle control valve needing added to the 6-12 months service.
That's the good news though because engine-wise , nothing else happens :D
Hopefully it's a connector problem ;)
--------------------
Oxygen sensor.

My faults were usually voltage related.
With this car one of the wire's sheathing had completely split millimetres from the sensor, unseen at first because it was under the heatshield tubing. If the connector cleaning doesn't work I'd try there next.
Expect to pay £60-£70 for a new one, all because its got an extra wire lol.
-------------------
Camshaft sensor.

-A bit of a nuisance when the eml activates randomly :roll:
Since you've replaced the camshaft sensor I'm assuming it's the modified one where you have to cut off the old plug and splice the new one in?
The splice is usually the weak spot and checking will probably fix it :)

If you can, avoid removing the sensor as it's a bit of a pita.

If done carefully you can ease the timing belt cover back but you have to be careful not to break it, it'll be a bit brittle after all these years.
Silly design really, if they'd reinforced the top of the cover a little the same bolt could have secured the cam sensor and you would be able to remove it easily instead of having to remove more bolts.

If you're removing the cover might as well check the needle position of the timing-belt automatic tensioner, it may need adjusted.
------------------

Although it won't solve these particular problems I'd advise cleaning out the icv.
I have a spare cleaned and ready for the next time the engine stalls crossing into a street :p
" It's not rust. It's age-related patina " ;)

1980 vauxhall cavalier MK1 1.6L, 1982 opel manta berlinetta 1.8s, 1985 opel manta 2.0 gte, 1990 cavalier 2.0 gl ,1994 cavalier sri x20xev

-1995 cdx x20xev

---------------
Matt
Joner1983
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Posts: 135
Joined: Thu Jun 16, 2011 10:50 pm
Location: Swindon

Re: 1995 SRi X20XEV won't start

Post by Joner1983 »

Since you've replaced the camshaft sensor I'm assuming it's the modified one where you have to cut off the old plug and splice the new one in?
The splice is usually the weak spot and checking will probably fix it 
Yeah that's the one. I changed it about a year before I garaged it up so getting on for 7 years ago. I've ordered a new intermotor one just in case cleaning the connection and checking the makeshift splice doesn't cure it.

I've had the IACV off and it seems to be clean and free moving. Again this was new shortly before it came off the road.

Where exactly is the oxygen senson located?
1991 H White 1.6L
1992 K Burgandy 1.6L
1989 F Lt Blue 2.0 CDI
1992 J Spectral Blue GSI2000
1995 M Black 2.0 SRI 16v Eco
1995 N Grey 1.8 GLS
1990 G Met. Red 2.0 SRi 20seh
1994 L Grey 2.5 V6
1992 J White GSI2000
So far...............
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Robsey
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Posts: 10619
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: 1995 SRi X20XEV won't start

Post by Robsey »

Look on the front down-pipe, just before the flexi-joint to the catalytic converter.

Sadly it means getting under the car to access the sensor.
The connector should be up near to the coolant header tank on the bulkhead.
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