2004 Ford 1.8TDCi Questions (F9DA engine)

[VanDiesel99]

2004 Ford 1.8TDCi Questions (F9DA engine)

Hi; couple of questions please for anyone with a bit of knowledge of these, which is probably plenty of people, them having been very common.

1: has anyone got an inlet manifold with EGR for an early type engine (Endura 1.8TDCi, last of the Mk1’s). There doesn’t seem to be much ‘early’ stuff about. My Turbo isn’t boosting as well as it should at low revs and I’m inclined to blame the EGR, but I’m loathe to ‘play with’ mine until I’ve got myself one from a scrapper, to understand it better.

I’d be tempted to buy an entire engine if I can find one at a sensible price (not necessarily in running order), as a ‘learning tool’, in a similar way to how I did with my Pug. I've ended up with two spare engines for that, the more expensive one cost me £50

2: I’m experiencing an occasional loss of power, it’ll ‘miss’ for a second or two, maybe once in the course of a 30mile journey, always while NOT under load, at a constant speed, neither accelerating or slowing down, and at fairly low engine revs, maybe 1500rpm to 2000rpm. It's so brief that there's no time to be concerned.

I’m thinking that air is entering the system, as I experienced something similar shortly prior to my Fuel Pump dying on my Pug XUD years ago. I’ve visually checked the Injector Unions and pipework and there’s no evidence of any leaks. Its not really a problem yet, but if it gets worse while I’m on holiday 500miles from home; that will certainly be an issue.

My thinking is to put a clear bit of Hose in the system and change the Fuel Filter (early canister type) while I’m at it, but not until I’ve added a Fuel Priming Pump…would this go on the low pressure feed to the Injection Pump, or on the return?

There’s plenty of videos on YouTube, showing how to do this on Mk2, and I’m sure th same principles will apply.

It looks like I DO have a Pump, but I thought this engine (F9DA1 / TDCi) was Common-Rail…

(as I understand it, it’s the earlier FFDA / TDDi, that’s indirect injection)

I did all my own maintenance, including engine changes and welding on my previous Peugeot 405 XUD that I kept for over 10 years (some of you might’ve noticed it on eBay in December, a white N reg Estate) so while my Focus is 17 years old, it’s a big step forward from what I’ve been used to.

I believe however that I don’t have the ‘Floating Crank Pulley’ that the Mk2 has

…and I know (having recently changed the Water Pump, due to play in the bearings) that I do have the rather surprising Timing Belt AND Chain arrangement.

[VanDiesel99]

I couldn't get the second image to upload, so its here

There seems to be a separate mechanically driven pump?! So, that'd be indirect injection [confused].

Obviously, there's slight damage visible to the protection on the low pressure fuel feed, but the pipe seems to be fine; howeer changing that will obviously be one of my first ports of call, once I've got 'Fuel Priming' sorted