Year of Manufacture *: 2007 Engine Size and Code *: 2.2 litres 4HU ( Optional ) Scanner Used: Solus ( Optional) Fault Codes: P0401,P0103,P0530,P0683,U1601,U1700
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.
Hi Kevin, As P0401 was insufficent flow detected I put it down my list of priorities a bit, but I am now concerned that the EGR is stuck partway open, which could be the case and would affect the MAF readings and cause the black smoke. As is usual access is very awkward working through the letterbox that is the bonnet access on this. If I need a ramp to get at the EGR I can't do that until next week as I don't have one I'm afraid (being an electrician, for most jobs one would get in my way) so I would need to use the one in my friends unit next door. In my experience a stuck open EGR lets the vehicle start at first and then chokes the engine to death, or was that just the exception? I would have liked to blank the EGR temporarily but the junction with the inlet manifold seems to make this practically impossible. Hi Mark, I haven't done a relative compression test, is this supported on Solus? As this seems to be the only thing I've got that talks at any meaningful level. I could disconnect the injectors and do it with a 'scope of course. Thanks for taking the time guys, it's been a difficult week and sometimes it's hard to see the wood for the trees! Shaun
Just a thought on the egr, why not smoke the inlet and see if it holds pressure, if a egr is stuck open then pressure will be low and flow high and smoke emitting out of the tailpipe.
if it holds pressure activate the scan tool and see the egr in action via pressure/flow readings.
a thousand times easier than removing any egr valve.
Here is my ten pence worth. It has been a while since I saw one of these but I certainly remember how difficult they are to work on. Marks idea of relative compression is where I would start, to me my first impression is either lazy injectors (low pressure, heavy fuel from cold, lack of use)or a slight lack of compression from cold, possibly gummed up rings. Low mileage is great when you do not want the vehicle abused but 100 miles a month is not doing this any favours, 45,000 how many services has it had. These things are designed to be used. maybe worth trying a good quality oil flush once the engine is hot see if you can restore a bit of lost compression. Low flow may be an EGR fault and could cause bad starting but why would it fix itself once running. I may be wrong just my thoughts on the problem.
on July 11, 2014, 4:32 pm, in reply to "