lewiseyers

Hi,

just on the off chance for some expert help from you guys

i have a mondeo tdci 2.0 with delphi pump, ive sourced a new pump for £400 does any one know which fuel lines i need to replace or flush,

i am thinking is there any special tools that are needed to fit it,

i have a fairly decent mechanical ability i did the starter motor with ease and the pumps near it

does any one know of a step buy step guide on the net is there any code programming as like with the injectors im trying to keep the car on the road and costs down as i love the old girl, are there any tell tale signs that the pumps the problem if i leave the car too long it wont start and was running well rough with in a few weeks of changeing the filter

DanW@FastFord

iTrader: (1)

No special tools - and flush all the lines out (and tank) if your existing pump has broken up. I don't know of any guides online but it would be well worth putting up a post on talkford as there's bound to be people who have done it on there.

Be really careful, as even the slightest bit of contamination will have you chasing injector problems for ever (speaking from personal experience!)

lewiseyers

how does the pump come out is it not driven by the cam chain, meaning removal of the cam chain cover

so, if i take off the fuel filter and pour contents on to a pure white sheet of paper this would be how i would find out if the fuel pumps gone due to microscopic fillings in the fuel?

have you ever dropped the fuel tank is it some thing i could do at home,

i am thinking ill check the filter and see if theres fillings if there is ill drop the tank and take to car wash to jet clean out then thouroughly allow to dry,.thathen re fit but not the fuel lines just yet.... is that ok for the tank,

fuel lines.......
ill blow compressed air down the fuel lines, with a compressor from the tank end and hope fully blow any stray fillings through, and blow through the other one from filter to pump and the one from pump to the rail, are ther any more to clean?

Q. is there any valves or any thing iin the line to prohibit the line being blow through,

ill buy new pump and filter and fit and reconnect fuel lines and get fresh fuel ...is there any way i can check the injectors, they just been re conditioned buy mondeo spares with out codes though( i know this is not proper job by mondeo spares.co.uk stoke on trent) you have all told me if id known id never of had it done by them, or should i get them re conditioned again with a code this time

im in a bit of a situation the cars not worth much but i love it, its so practical if i can get it going again ill easy keep it another 3/5 years every thing that can go wrong has been done except the dreaded fuel system.lol

is there any thing else on these that goes

ive done starter and dmf both, rear calipers, injectors, air flow sensor

DanW@FastFord

iTrader: (1)

Sorry, misled you - You DO need to lock the timing chain sprocket. I meant that the pump isn't coded to the engine.

I found this which will be useful, and should answer your questions...

http://www.fordwiki.co.uk/index.php?...mp_Change_TDCi

You need to get the injectors recoded - which involves putting them in machine which creates a code based on the injector's tolerances. Then that code can be stored in the ECU so the car knows how to treat them. You could just try inputting the code that should be on the injectors now - but I suspect that they'll be a long way off if they're second hand ones from Mondeo Spares.

DanW@FastFord

iTrader: (1)

Just to add - Make VERY sure it's the pump that's failed before you attempt the swap. It's not a small job and it may not be the cure. It could be the IMV, the injectors or something else... Have you had the fault codes read?

lewiseyers

whats the imv

lewiseyers

the car was not running un less towed,

ive been under the bonnet all afternoon and removed all injectors and checked and double checked and writen down the codes on them and checked the codes against the sticker on rocker cover- they all match as i expected as they were my injectors that were sent off to be reconditioned,

Any way i made a filter out of new a4 white paper and emptied the fuel filter contents in to it and there was nothing no filings that i could make out at all, i re primed the filter, ( its only 700 miles old and refitted) making sure at all times to clean every thing with clean kitchen towels,

I refitted all injectors taking care to stay clean at all times and realised that the return to the fuel filter of each injector has a clip thats a little pig to get snapped shut fully and secure, even though i though id just clipped all on secure when doing a recheck before finishing up for the evening i realised that one was not quite Snapped shut, good job i rechecked as im sure a air leak here would leak are in to the filter and cause a non running engine which had happened,

i then bled of each injector and the cold engine of the car started on the button, thrus ruling out the glow plugs, i think i had a air leak on the return clips i have thoroughly checked all seals now car is running in limp home mode with what i believe to be a good fuel pump, i now have all injector codes written down so its of to ash automotive new ash green later this week to check the programming, im just wondering will it start in the morning once its had time to leak a bit of air in to the system or have a cured that part of the fault,

so the reasult of this afternoons work is im feeling positive its now some thing minor like a injector has forgot its coding or some thing, fingers crossed ill keep the thread posted

lewiseyers

i already read that ford wiki page buddy, but thanks for taking the time to help,

DanW@FastFord

iTrader: (1)

If the injectors were properly reconditioned then they should come with new codes.

Have you not had the fault codes read?

The IMV is the Inlet Metering Valve (on the fuel pump, and seems to fail more often than the pump itself)

lewiseyers

yes i did have fault codes read

alternator was and is over charging at 130%

and cylinder 2 above knock threshhold what ever that means since then the injectors were reconditioned but still no differance

there was one other code that i cant remember

DanW@FastFord

iTrader: (1)

Injector 2 is goosed and wasn't properly recoded. It can be very hard to reprogram the injector if there is a fault code attached to it – I pretty much guarentee that's the route of your problem.

You ideally need to get a new injector and them all properly recoded. Having said that, when one goes, the rest are always close behind.

Get the alternator sorted too, that can cause all manner of issue, and can damage the ECU, and other components.

lewiseyers

its going in to ash automotive new ash green kent later this week the guy that owns it andy is pure genius my local delphi specialist meopham garage the railway sidings meopham dont wanna know, ill keep you posted on progress i feel theres a few issues that are contributing, i love the car though and have decided that to buy some thing better that i will like will cost 6k so i dont mind working through a grand and a hlf getting it going sweet. its a tidy solid motor that does every thing so well, with a tow bar fitted ill easy keep it another 5 years i reckon, if i buy a 2k car im just buying some one elses knightmares possibly so i say better the devil you know, and in to ash automotive it goes he codes and fault finds on these to often he does a lot of x type jags on a weekly basis..

ill keep the thread posted next week ...

the_frozen_one

iTrader: (1)

7mm drill bit and a 4mm bit iirc, pump is timed to the 7mm hole in the cam pulley, not the smaller one. Peg the engine there, use the 4mm to hold the backlash on the pump box if applicable, and line the dots up pump gear to drive gear

lewiseyers

turns out a transit forum member lives a few doors down from me and has a lot to bo with transit mechanics and has the fault code reader he mentioned that he programmed the code in a vauxhall s injectors the other day...

ive heard rumours about fault code readers though some of them are no good which ones are the correct ones, i will keep the thread posted

the car is still running in limp home mode and a pig to cold start and occasionally cuts out

lewiseyers

progerss report

a transit specialist read the codes today knock threshhold code has gone since new injectors went in so has electrical code,

i have two codes now and they are

low pressure at injector-or rail?

and high pressure at injector- or rail?

a leak of test was done in my presence with ive never seen done before so i was interested to watch, barely ten or 12 drops leaked back from any injector and the all leaked back in a very balanced way e.g the same amount each, the tester assured me this was a very healthy test and it would seem the injectors seem ok..

The engine was running for 5 mins during this test, there was lots of bubbles coming up the clear test pipes though,from every injector, and a couple of the clips were the pipes connect to the injector were found to be suspect this would leak air back in to the filter and then recirculate around the injection system apparantly and cause crap starting and running,

so a brand new set of return pipe and all associated clips are on the way,
and if that does not work the guy said new pump, i mentioned the (imv) he asked me to fing out more about it, were is it on the pump and is it repairable and were would i get one

i can get a re con pump for 400 which seems like a steal..

all advice appreciated were could this air be coming from the pump?

lewiseyers

found imv on end of the pump! god i was looking every were, i feel like im getting close to sorting my injection system out here

lewiseyers

http://www.talkford.com/topic/163021...51p1211/page-2

i read the above thesre is air coming out of the transparant test pipes a steady continuious flow from all 4 barely any fuel though and the tester deemed it a healthy set of injectors, i have new fuel return lines and fitting going on do you suggest the imv next

lewiseyers

got pump with imv valve fitted looks mint i know that means nothing in real world term


im picking up in the in the morning of ebay gotta pick it up, it will go back on ebay if it does not help so minimal money lost there,

ill keep the thread posted

DanW@FastFord

iTrader: (1)

Good progress. Injector/fuelling issues are such a pain to sort. I was battling with mine for a couple of years before it ran ok.

The clips definitely do seem to cause issues, so it's very wise to fit them first because they're simple to do.

If that doesn't work it may be worth swapping the IMV rather than the whole pump for a start - At least to rule it out! Just do one thing at a time to help diagnose it.

Be aware that faulty injectors can still pass a leak off test (mine did) but I'm aware this seems to be very rare. I ended up having mine on a Delphi test rig (which tests a huge number of parameters) and they were found to be shot, despite 'passing' a leak off test before. But as I said, this does seem to be the exception, rather than the rule.

I used the Delphi Diamand kit to recode it (the same Ford use) and even with that, and a very senior bloke from Delphi on the other end of the phone, and it was still a bitch to recode - hence my earlier comment.

lewiseyers

well i got a really mint pump and imv ready for lunch time tomorrow and we already decided change imv and fit new return hoses first, i may even keep none faulty parts as spares,

who did your injectors colchester diesel?

failing all tomorrow the crank sensor is being check for swarf from the dmf replacement and then it whole injecton systm off from tank to injector clean inspect and replace the whole lot,

i was told theres a software update from ford i may need too

lewiseyers

was wondering if the petrol mondeos suffer from much as i my sell and get a petrol ghia of titanium

DanW@FastFord

iTrader: (1)

There may be, but it won't be the cause of your troubles.

They have their own issues, but do seem to be less of a ball ache when they go wrong.

The problem with the TDCI is that when they work they're great - and there are many many Mondeos that work faultlessly for huge mileages (a taxi rank round here only uses TDCI Mondeos because he's had so much grief with other diesels) But when they do go wrong, particularly if it's the fuelling side that fails then it's almost always a complete ball ache to sort, and seldom cheap!

lewiseyers

would you ever by a tdci again? you sound like you had your fair share of problems, did yours stay reliable and just run rough or give up the ghost

lewiseyers

up date

got pump and imv today of ebay with moneyback offer from seller so happy days had to drive 30 miles to get if but the money back offer is worth it i say, will be fitted in next couple of days

new leak off pipes and connectors first then

imv valve second then if nessercary complete pump and imv

DanW@FastFord

iTrader: (1)

I've got a Mk4 TDCI now but it's a different engine - I'd never touch a Mk3 again. It only actually broke down on me once in all the time I had it - but it took two years to get it to run right.

lewiseyers

new injector fuel return to filter pipes and imv / fuel pressure regulator have been changed no differance, wont run properly even in limp home mode now!

I should not of let a neighbour who "rates his mate" have a look, £300 later its worse

Im getting lots of air out the injectors and cant hear any pump at the rear end in fuel tank how would i test it, just take of pipe at fuel filter and try to start?

off to ash automotive with it friday

lewiseyers

from your experience is there any places in the gravesend dartford medway n/w kent area you would trust to look at this car who actually know what there doing

lewiseyers

the seal on the fuel pressure regulator needed replacing, a injector was out of code, and this is the shocker

DO NOT USE THIS INJECTOR RECONDITIONING SERVICE...

MONDEOSPARES.CO.UK from stoke on trent re conditioned my injectors they never re coded them or did a proper job at all real cowboys! and left one of the injectors re assembled and re tightened together finger tight!!! the nozzle was rattling about in the cylinder,

the car is out of limp home mode and fault codes cleared, but there is still some diesel clatter that was never there and a clicking when car comes off full boost

But car is completely use able.

ill get it tuned up and looked over a bit more thoroughly and do all the aux belts and tensioners now