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Old 11-03-2011, 06:28 PM   #1
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Default Ford Transit Connect TDCI- Will Not Start!

Basically, I brought a transit connect 2004 90ps.

The van had a broken con rod when I picked it up (I brought it as a non runner)

I have fitted a replacement engine and it refueses to start. It will start on easy start but cut out as soon as it's all used up.

When we fitted the engine we used everything from the old engine so as not to get a coding issue.

We've used a hand pump to suck diesel from the tank and prime the system.

If you crack an injector nut off totally when cranking you get a load of air out and then fuel dribbles out at no great speed.

I've plugged my dynostics into it at it comes up with :- P2291- low injector pressure when cranking.

Is there any way of totally bleeding the system or bleeding the pump?

I seems to me like the high pressure pump has shit itself but it must of worked for the old engine to break a con rod?

You can tell the van was moving at speed when the rod went as there's oil all over the rear bumper and all over the underside of the van.

Any ideas.

Cheers.

Mike
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Old 11-03-2011, 06:31 PM   #2
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Can you try towing it?I've found with many modern diesels this is the only way.
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Old 11-03-2011, 08:20 PM   #3
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The way a bleed the fuel wilters is to get an electric fuel pump and put 1 pipe on the fuel filter and another pipe on the end of the pump and suck the fuel through.
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Old 11-03-2011, 08:29 PM   #4
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as said tow it, had to do this after changing filter on 1 and bleeding it
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Old 11-03-2011, 08:42 PM   #5
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An airlock in the system could potentially cause that fault code, so it doesn't necessarily mean the pump is goosed. It's not a good idea to turn the car over too many times without it firing as you can damage the pump quite quickly!
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Old 11-03-2011, 08:55 PM   #6
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Have you got the new engines injectors? On some of the connect tdci's you dont have to code in the injectors could be worth while tring them.

They can be a bit of a bitch to bleed off, i normally take the middle pipe off the fuel filter and put a hand primer on until the fuel comes through then connect the other side of the primer to the pipe and pump it through then it should start.

Good luck
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Old 11-03-2011, 09:16 PM   #7
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done some work on a transit which had run out of diesel; the thing refused to start after it was filled back up - tried loads of stuff, before finally giving up and dragged it up the road
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Old 11-03-2011, 09:40 PM   #8
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Just tried tow starting it and the glow plug light started flashing.

I've now got code P0251:- Injecton pump fuel metering control A malfunction
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Old 11-03-2011, 09:41 PM   #9
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I've re-coded all the injectors just incase.
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Old 11-03-2011, 09:45 PM   #10
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Originally Posted by Tank Mike View Post
Just tried tow starting it and the glow plug light started flashing.

I've now got code P0251:- Injecton pump fuel metering control A malfunction
Have you still got the broken engine, and tried swapping over the fuel rail sensor, inlet metering valve, cam sensor, and the crank sensor just to to rule them out?
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Old 11-03-2011, 09:47 PM   #11
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make sure the regulator on the pump[i think thats what its called] is very very tight as i had a similar problem ,i couldnt get the engine to fire off and it seemed to be getting enough diesel .i rang a diesel specialist and he said its quite common and to tighten it really welll as it will draw air
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Old 11-03-2011, 09:57 PM   #12
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The new engine was literally a bare block and head with the valves and pistons ect.

Everything to do the the Injecton system, sensors, pipes, cam, the lot are from the original engine.

I've just cracked off the injector pipe again and cranking it and a load of air came out followed by a dribble of diesel.

Does anyone know how to fully bleed the system?

I've connected a hand pump to the supply from the tank, to the outer pin on the filter and pumped till diesel came out. The I connected the other two pipe, cracked off all the injectors and pumped like mad for about 15mins, ( I didn't get any fuel out the injector pipes but I'm not sure your meant too, I know you do with TDDI)

Other than that it must be drawing in air somewhere as stated above.
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Old 11-03-2011, 09:59 PM   #13
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Quote:
Originally Posted by james kiely View Post
make sure the regulator on the pump[i think thats what its called] is very very tight as i had a similar problem ,i couldnt get the engine to fire off and it seemed to be getting enough diesel .i rang a diesel specialist and he said its quite common and to tighten it really welll as it will draw air
Any idea where this is on the pump?

Is it one of the sensor looking things on the back of the pump? I think on mine one has a blue plug and one has a brown plug.
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Old 11-03-2011, 10:00 PM   #14
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Did you bleed it from the leak-off pipes?
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Old 11-03-2011, 10:01 PM   #15
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sure there isnt any small breaks/ splits in any of the fuel lines so air is being drawn in?
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Old 11-03-2011, 10:21 PM   #16
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Did you bleed it from the leak-off pipes?
No. I haven't touched the leak offs. Looking at the roughting of the leak offs the pipes go into the return of the pump. That then goes back up to the filter. I'd imagine when I had the hand pump on the filter, diesel was pumped backwards down the return.
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Old 11-03-2011, 10:35 PM   #17
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Could be injectors mate i have had to change a few injectors when the engines have let go
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Old 11-03-2011, 10:47 PM   #18
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Trouble is the injectors are £150 a pop and a pump rebuild is £600

One of the injectors is brand new and been coded

Diesels are so bloody expensive when they pack up!
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Old 12-03-2011, 07:17 AM   #19
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On your diagnostics can you access live data from ECU?

To test the Fuel rail pressure, disconnect all the injector multi plugs and the inlet metering valve (brown plug on the 'pump') then crank for 5 secs. Fuel pressure should be 1600bar. It'll need 250 bar to start/idle with everything plugged in.

(with the IMV disconnected the pump should deliver it's maximum pressure)

Obviously you need to make sure the low pressure side is primed before doing this!

As others have said, hand primer on the filter normally works, I've never cracked off the injectors on a TDCI when trying to start it, never needed to. Surely that will draw air in..

If you have P0251 it could be a pump problem, but it could also be fault with injectors/air leaks/filter blocked/fuel pipes crimped.

With fuel low pressure side primed and fuel pressure tested, if the pressure is low you need to do a leak off test on the injectors.

Click the image to open in full size.

(random google pic)
If you haven't got the fancy kit to test leak off, just get 4 EQUAL lengths of washer pipe that'll fit on the injector leak offs and 4 tubs/bottles/whatever that are transparent.

Again disconnect the injectors and inlet metering valve, and 5 sec crank and check if fuel is present in any of the hoses, if one has a load of fuel in, there's your faulty injector that is losing your fuel pressure!

If you can get it started, you can run it with the leak offs into the containers and run it for a minute to see how your leak offs compare.

When Transits and Mondeos had all the injector problems we had to ring Ford prior approval to get them to authorise the replacement under warranty, proper ball ache having to go through the results of all of the above, plus compression test results...

Ford prior approval : "whats your 1 min run test leak off quantity"
GVK - "Haven't done one"
Ford prior approval "Why not?"
GVK - "It fills the bottle in 30 secs, If I run it for a minute it'll piss diesel on the floor!
Ford prior approval "Oh, errr, I see - fit an injector in that cylinder then.."
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Last edited by GVK.; 12-03-2011 at 08:01 AM..
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Old 12-03-2011, 11:37 AM   #20
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Think I've found the issue!

No. 3 injector just pisses diesel out the leak off. I mean pisses it out! I'm off to get a new injector, so fingers crossed we should have a result by thisafternoon
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Old 12-03-2011, 03:23 PM   #21
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Good luck
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Old 12-03-2011, 03:32 PM   #22
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Started first flick with the new injector.

Thanks for everyones help

Now I've got a new problem that I'll start a new thread for. It aboslutly pisses oil out from the crankshaft oil seal behind the pulley. I've tried another seal but it still pisses out!

I know the oil pump is behind the pulley. Any ideas?
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Old 07-07-2012, 02:16 PM   #23
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Hi i have the same problem with my mondeo just about to do the leak back test. i have a question if you want to start the car or try to do you plug the imv back in? clearly you have to plug the injectors back in any advice would be gretfully received.
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Old 07-07-2012, 02:22 PM   #24
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Injectors on the 1.8s are like dominoes. You'll have to change another within 3 months...
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Old 07-07-2012, 02:33 PM   #25
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i know but i just want to get it running for now. that will be fine.
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Old 07-07-2012, 02:43 PM   #26
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ok just done the nleak off and nothing on any injector i was expecting a little from all but nothing not even a dribble. Should there be? i did change the fuel filter recently and i am expecting it is dud!! i do not think there is fuel reaching the injectors? any idea's?
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Old 07-07-2012, 03:20 PM   #27
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ok just done the nleak off and nothing on any injector i was expecting a little from all but nothing not even a dribble. Should there be? i did change the fuel filter recently and i am expecting it is dud!! i do not think there is fuel reaching the injectors? any idea's?
Has it started since the filter change?
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Old 07-07-2012, 04:27 PM   #28
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yes it has run sine the change but gor progressivly harder to start and would cut out whe cold! i am now thinking this is the problem
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Old 09-07-2012, 07:32 PM   #29
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Ok update i have learnt today some of these cars came with a low pressure fuel pump you can buy them on ebay. anybody know where they are located?
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Old 15-07-2012, 06:10 PM   #30
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So another update my problem was caused by a new faulty bosch fuel fileter, i knew ir was not right the second i removed it as it was only 1/4 full of fuel. fitted a new delphi filter took my time priming it and problem is no resolved. car runs well and fires up as it should. i had only done 500 miles on the bosch filter!!!!
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Old 05-09-2013, 07:15 PM   #31
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Quote:
Originally Posted by GVK. View Post
On your diagnostics can you access live data from ECU?

To test the Fuel rail pressure, disconnect all the injector multi plugs and the inlet metering valve (brown plug on the 'pump') then crank for 5 secs. Fuel pressure should be 1600bar. It'll need 250 bar to start/idle with everything plugged in.

(with the IMV disconnected the pump should deliver it's maximum pressure)

Obviously you need to make sure the low pressure side is primed before doing this!

As others have said, hand primer on the filter normally works, I've never cracked off the injectors on a TDCI when trying to start it, never needed to. Surely that will draw air in..

If you have P0251 it could be a pump problem, but it could also be fault with injectors/air leaks/filter blocked/fuel pipes crimped.

With fuel low pressure side primed and fuel pressure tested, if the pressure is low you need to do a leak off test on the injectors.

Click the image to open in full size.

(random google pic)
If you haven't got the fancy kit to test leak off, just get 4 EQUAL lengths of washer pipe that'll fit on the injector leak offs and 4 tubs/bottles/whatever that are transparent.

Again disconnect the injectors and inlet metering valve, and 5 sec crank and check if fuel is present in any of the hoses, if one has a load of fuel in, there's your faulty injector that is losing your fuel pressure!

If you can get it started, you can run it with the leak offs into the containers and run it for a minute to see how your leak offs compare.

When Transits and Mondeos had all the injector problems we had to ring Ford prior approval to get them to authorise the replacement under warranty, proper ball ache having to go through the results of all of the above, plus compression test results...

Ford prior approval : "whats your 1 min run test leak off quantity"
GVK - "Haven't done one"
Ford prior approval "Why not?"
GVK - "It fills the bottle in 30 secs, If I run it for a minute it'll piss diesel on the floor!
Ford prior approval "Oh, errr, I see - fit an injector in that cylinder then.."
i have a simular problem if i disconect the plug on the imv will i get full fuel pressure and no limp home mode light... im stuck... i have a thread

http://passionford.com/forum/ford-mo...ial-tools.html
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Old 05-09-2013, 07:19 PM   #32
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You only disconnect the imv & injectors to test the fuel pump and injectors as it should give maximum pressure, if any injectors are leaking off excessively you will lose fuel pressure during the test I have described above.
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Old 06-09-2013, 10:43 AM   #33
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Quote:
Originally Posted by GVK. View Post

Ford prior approval : "whats your 1 min run test leak off quantity"
GVK - "Haven't done one"
Ford prior approval "Why not?"
GVK - "It fills the bottle in 30 secs, If I run it for a minute it'll piss diesel on the floor!
Ford prior approval "Oh, errr, I see - fit an injector in that cylinder then.."
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Old 06-09-2013, 11:58 AM   #34
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True story after a day faffing about to get authorisation to fit a set of injectors.
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Old 06-09-2013, 11:58 AM
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