I should have posted this one earlier as it is going back to the customer for the moment.
This appears to be the Ford engine.
The problem has apparently developed slowly over the last year.
When starting first thing in the morning it really needs "winding up" and may need to crank for about 30 seconds to get it to go, for the rest of the day i.e.when warm, it is fine.
The vehicle is kept in the stores overnight and is moved in and out daily, only really being used in anger at the end of the month for deliveries.
The vehicle is low mileage at 45500 miles and little used, 100 miles a month approx.
The only code that returns is the glowplug code and number 3 plug measures 16 Ohms, the others were all good at 0.7 Ohms. Replacing the plug may help a bit I am sure that is not the root cause of the problem.Replacement of the plugs is not a five minute job as the manifold needs to come off.They were also replaced in January with no noticeable improvement, No3 is either an early failure or the garage that did the plugs couldn't get it out and left the old one in.
Checking the fuel rail pressure sensor with a meter shows 1.5V (correlates with 300bar on live data)promptly and consistently when cranking. When attempting to start, the engine fires on one or two cylinders for a long time until they all chip in and the engine starts. There is an accompanying smell of unburnt diesel and blue/white smoke, not a huge amount but enough to notice. There is also some black smoke when revved, again not huge but noticeable.
Injector corrections show No1 at -0.70, No2 at -1.0, No3 at 0.18 and No4 at 2.15.
So it appears it's injecting but not burning. The customer knows that we may have to remove and get the injectors tested/re-conditioned but I am also concerned that there appears to be the possibility of the cam chain tensioner relaxing and causing late cam timing unitl the oil pressure is up to spec.
Anyone with any history on these engines able to give me some pointers so I don't reinvent the wheel on this.