INLET MANIFOLD

westportpoultry

Had problem with my car Mondeo TDDI 2.0 Diesel.

*Failure to start when hot
*Low on power in low gears
*Rough Idling
*Heavier on diesel more than usual
*Car will start when disconnect Coolant Temp Sensor.(Fan Permanently on)
*Also starts when rolled down a small hill.

Diagnosed as Fuel Injector Pump(High Pressure Pump)

Today i was taking off Inlet Manifold Intake to find part number on HPSU Fuel Pump. On removal of Inlet manifold I noticed it was caked in Oily Gunk quite a bit.
What causes this build up???
How to clean??
Could this be my underlying problem as described above?
Pictures included.

http://i922.photobucket.com/albums/ad66/cossworx/website%20%20images/Car/011.jpg
http://i922.photobucket.com/albums/ad66/cossworx/website%20%20images/Car/008.jpg
http://i922.photobucket.com/albums/ad66/cossworx/website%20%20images/Car/002.jpg
Thanks in advance.

Chimaera

That gunk is a mixture of oil and soot. All modern diesel engines recirculate a certain amount of the exhaust back into the engine intake for emissions purposes. This can carry a bit of soot back. Additionally, it's pretty common for the crankcase breather to be routed into the engine intake. This will carry oil vapour and droplets. These mix in the intake manifold creating that gunk.

Best way to clean it is soak it in diesel for a few days. Fill a large container with enough diesel to immerse it and leave it. The worst of it should come out then.

It's unlikely to be the cause of the hot start problem, but it could well be part of the reason you're using too much diesel.

westportpoultry

Thanks was thinkin im back to square one. Cleaning manifold shouldnt be too much a problem.

If its injector fuel pump thats faulty how does this effect hot start?? Cheers!

westportpoultry

Thanks was thinkin im back to square one. Cleaning manifold shouldnt be too much a problem.

If its injector fuel pump thats faulty how does this effect hot start?? Cheers!

George Dalton

That level of soot buildup is totally normal and won't be the cause of your running issues.

I have never seen an injector pump cause these symptoms on a Mondeo.

What year is the car?

How did you arrive at this stage where you have diagnosed the injector pump as being faulty? Did you have a diagnostic scan done and if so what were the codes?

westportpoultry

Its a 2002 model. I bought it off a fella cheap seemed to run fine but when tried starting from hot it wouldnt. It would start then again when cooled down or if it was rolled down a hill. So i discovered whe its hot by disconnecting engine coolant temp sensor it would start but running cooling fan also. Power is brutal in it. Hill climbs are tough. Had it in 3 garages and they hadnt a clue. Fuel filter replaced. Ford Diagnostic in sligo showed up nothing. Then at last garage showed up coolant temp sensor fault and fuel injector fault. Not sure of codes. Also talked to a guy in diesel remanufacturing place he said it was pump just by symptoms. He was working on same pump at time. Im still not convinced. Can pump be diagnosed and confirmed faulty outright?? They have their own ecu. It drives in high gears decent enough reaching 70mph at least. Cant understand how any garage can confirm a problem outright. Sligo said wiring fault but i reckon bull crap.

George Dalton

The pumps electronics do give trouble on them but your symptoms don't match. If this is a pump problem then it is more likely to be in the mechanical part of the pump.

The coolant temp sensor fault is to be expected given the fact that you were experimenting with it by unplugging it.

I would like to know what the other injector related fault was.

One thing I have seen with a good few of these TDDI Mondeos and Transits causing difficulty starting or even outright non starting when hot is faulty timing chain tensioners. I once mistakenly changed an injector pump on a 2005 Mondeo before realising the chain tensioner was the actual culprit. I suggest you learn from my mistake and make sure the pump is the problem before changing it

westportpoultry

Yes I have thought that today I need to be certain about pump failure. Is it much work for a garage to check this timing chain? Im told pump can be diagnosed it has its own socket/ecu? How ya mean other injector related fault? Im going to blow the car up next week if i dont get it sorted i think!!

George Dalton

Yes there is quite a bit of work involved in checking the chain unfortunately.

The pump can be diagnosed separately by plugging straight into it with Bosch KTS diagnostic equipment.

The other injector related fault I was talking about was the one you referred to in your previous post:

Then at last garage showed up coolant temp sensor fault and fuel injector fault. Not sure of codes.

westportpoultry

I tried something today with this car. I disconnected the temp. sensor and i shorted the two cables going to the ecu. (cabled briding two together).
To my amazement it starts first time every time. Previously would not start with temp gauge connected. Would only start after 4-5 cranks with sensor disconnected. Now she starts first time every time but cooling fan running(draining power).

What da fock is going on here??????:eek:

Tea drinker

maybe the coolant temp sensor is really faulty?

westportpoultry

George Dalton wrote: »

One thing I have seen with a good few of these TDDI Mondeos and Transits causing difficulty starting or even outright non starting when hot is faulty timing chain tensioners. I once mistakenly changed an injector pump on a 2005 Mondeo before realising the chain tensioner was the actual culprit. I suggest you learn from my mistake and make sure the pump is the problem before changing it

Got both pump and ecu scanned today by (delphi diesel specialist). KTS SCANNER

Pump Scan shows no errors.

Ecu Scan shows the following.

P1288 Coolant Temp Sensor

P1665 Injector Pump Communication Error

P1608 Injector Pump Internal Fault

P0216 Injection pump time control(crank signal i think he said check this sensor)?

Scan of pump shows no fault tho. Faults were cleared but temp sensor stayed up. It was still disconnected.

This timing chain tensioner could it be da culprit? Could I check this?

Any of this ring any bells??? :rolleyes:

George Dalton

I would suspect either a wiring problem or a problem with the timing advance solenoid on the injector pump. The codes and symptoms don't fully match either a pump or chain problem, though it could still be either of them as well.