Ford Focus 1.6 TDCi starting issues
Discussion
Hello from Norway 
Seemed to be a lot of skilled people here at PistonHeads forums so I wanted to give it a shot!
I've got a ever so 'small' problem with my Focus, the car in question is a 2011 year Ford Focus MK 2.5 with a 1.6 TDCi 90hp, the well know s
tty PSA unit. This engine is really starting to piss me off to be honest, I am really in need of some extra brains here now...
Couple of weeks ago I decided to replace the injector seals as they have been leaking a bit for some time. Three out of four injectors came out fine, but the number 2 was rusted in place and had to be removed with a special 12ton pulley in which I needed to remove the complete air intake for space.
A relativity small and easy job became a very big job, ending up spending a weekend on it.
The injectors where then carefully cleaned with a bench grinder, the injector canals where all cleaned out, the pin bolts honding the injectors in place where replaced. The complete return pipe for the injectors where also replaced. I also cleaned out the air intake while it was already out of the car. Everything was put carefully together with new copper and rubber seals at the injectors, tightened up to correct torque. Finalizing the work, the diesel system where primed and fuel filter topped back up with a air-driven brake bleeder.
Moment of truth, the engine refuses to start.
I have no error codes, no leaks. All connectors and hoses triple checked, nothing is missed. The battery is good and the cranking speed is well above 200 RPM, altough I had to charge up the battery a couple of times. The diesel pump is working as far as I can see, and theres fuel all the way to the injectors. Undoing the pipe to the fuel rail comfirms it is actually producing. The system has been primed both at the outlet of fuel filter, and the return line coupling at the top of the engine, I have pumped out 15-20 litres of diesel in total. I've tried replacing the fuel pressure regulator, unplugging the fuel pressure regulator without sucess. All of the injectors are showing a resistance of 0 ohms, dont know if this is correct, but they all worked fine.
I have not yet checked if the injectors are getting singal from the ECU, but I think I need a oscilloscope for this. Also, I know the ECU wont let the injectors open before building up correct amount of pressure, or am I wrong?
Almost out of ideas, with the help of an assistant to help me with the the starter and gas pedal, I have also tried to inject start-gas. The car will fire on this, run for a couple of seconds up to about 1500 RPM, then die out again. I tought this will help it start as the diesel pump will pump alot faster with the help of start-gas. But no, the car still refuses to start. I have earlier had some small issues with the engine. A couple of times the last year or so, the car has suddenly lost power and starts to hesitate for some seconds, and then go back to normal again. It always accours when the engine is cold. The second issue was earier this winter, the car refused to start one morning. I localized a small leak from one of the fittings at the injector, and having fixed that and primed A LOT, the car started again. Maybe this has a connection with my on-going problem, I dont know.
Anyways, the only thing left I can think of is the high pressure pump is too weak or theres some fault with the ECU itself.
I have a video of the fuel pump when cranking. Seems a little weak to me?
https://www.youtube.com/watch?v=l-G6KNnlbi8&fe...
Thanks i advance.
Seemed to be a lot of skilled people here at PistonHeads forums so I wanted to give it a shot!
I've got a ever so 'small' problem with my Focus, the car in question is a 2011 year Ford Focus MK 2.5 with a 1.6 TDCi 90hp, the well know s
tty PSA unit. This engine is really starting to piss me off to be honest, I am really in need of some extra brains here now...Couple of weeks ago I decided to replace the injector seals as they have been leaking a bit for some time. Three out of four injectors came out fine, but the number 2 was rusted in place and had to be removed with a special 12ton pulley in which I needed to remove the complete air intake for space.
A relativity small and easy job became a very big job, ending up spending a weekend on it.
The injectors where then carefully cleaned with a bench grinder, the injector canals where all cleaned out, the pin bolts honding the injectors in place where replaced. The complete return pipe for the injectors where also replaced. I also cleaned out the air intake while it was already out of the car. Everything was put carefully together with new copper and rubber seals at the injectors, tightened up to correct torque. Finalizing the work, the diesel system where primed and fuel filter topped back up with a air-driven brake bleeder.
Moment of truth, the engine refuses to start.
I have no error codes, no leaks. All connectors and hoses triple checked, nothing is missed. The battery is good and the cranking speed is well above 200 RPM, altough I had to charge up the battery a couple of times. The diesel pump is working as far as I can see, and theres fuel all the way to the injectors. Undoing the pipe to the fuel rail comfirms it is actually producing. The system has been primed both at the outlet of fuel filter, and the return line coupling at the top of the engine, I have pumped out 15-20 litres of diesel in total. I've tried replacing the fuel pressure regulator, unplugging the fuel pressure regulator without sucess. All of the injectors are showing a resistance of 0 ohms, dont know if this is correct, but they all worked fine.
I have not yet checked if the injectors are getting singal from the ECU, but I think I need a oscilloscope for this. Also, I know the ECU wont let the injectors open before building up correct amount of pressure, or am I wrong?
Almost out of ideas, with the help of an assistant to help me with the the starter and gas pedal, I have also tried to inject start-gas. The car will fire on this, run for a couple of seconds up to about 1500 RPM, then die out again. I tought this will help it start as the diesel pump will pump alot faster with the help of start-gas. But no, the car still refuses to start. I have earlier had some small issues with the engine. A couple of times the last year or so, the car has suddenly lost power and starts to hesitate for some seconds, and then go back to normal again. It always accours when the engine is cold. The second issue was earier this winter, the car refused to start one morning. I localized a small leak from one of the fittings at the injector, and having fixed that and primed A LOT, the car started again. Maybe this has a connection with my on-going problem, I dont know.
Anyways, the only thing left I can think of is the high pressure pump is too weak or theres some fault with the ECU itself.
I have a video of the fuel pump when cranking. Seems a little weak to me?
https://www.youtube.com/watch?v=l-G6KNnlbi8&fe...
Thanks i advance.
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