Running issues after replacing injectors

[benwaterson]

Hi all

First post here -  Proace Verso  2.0 180ps DW10FC.

I replaced all 4 injectors (including cleaning and reaming the seats and new copper seals and new injector bolts).

Got it back together and coded them in diagbox, ran the priming procedure and also ran the injector actuator tests - no problems.

However it's now very difficult to start and when it does the idle is low and lumpy. Fuel pressure reading in diagbox looks ok at 300+ bar.

Pulled the pressure sensor while pump primes without starting and it squirts diesel from the hole in the fuel rail.

Is it likely to just be an air lock? Battery is flat from trying to start so left it charging.

Any hints or tips would be much appreciated.

Thanks

[flash22]

Clogged filter or duff glow plugs

[benwaterson]

Has new fuel filter and pressure sensor (about a month old) and car was running before injector swap - has 140,000 miles on it - started on the button before with old injectors, just had poor MPG (23 to 27 MPG)

[benwaterson]

Checked glow plug resistances and all 1 ohm, resistance of each wire in harness back the relay all 4.5 Mohm. I was lead to believe that the glow plugs were only used for cold weather starting on these engines?

Undid fuel return line connector and put a clear plastic bottle and around 300lm diesel comes out, no air bubbles.

Battery is flat again so charging up - I did note that if I undo the fuel filler cap the tank is pressurised to a certain extent (not sure if this has any bearing on this as assume its just the return pipe and any initial air purged from the system).