I own a 2003 Ford Focus 1.8 TDCi. On Jan 1st 2014 the bottom end went.
My mechanic advised me to get a replacement engine. The only one I could source was one without a pump or injectors but my mechanic said we could use parts from the old engine. Once the work was done the car went to the local Ford garage to have the injectors programmed to the new engine where they discovered the injectors were not suitable for the new engine.
One of the Ford techs said he works in a different garage at the weekends and that his boss had the right injectors, so the four replacement injectors were put in a programmed.

I eventually got the call to collect the car 5 weeks after leaving it with the mechanic and an £800 bill (I also paid £200 for the engine).
I was advised that the car was very smokey and that it would clear after driving a while. For two weeks after, the car was very smokey (blue) on start but cleared after driving for a while.
Now it fails to start. I sent it back to the mechanic on a lorry and he said the fuel system had air locked and that the car was now fine.
I collected it last Friday (Feb 28 2014) and on Sat morning it would not start again and has sat on my driveway since.
I was advised by a local motor factors to pull off the outlet pipe on the fuel filter and crank it a little at a time until fuel came out to get rid of any air.
On the first crank fuel came out so I assume its not air locked.
Can someone advise on what might be wrong as I have spent £1000 on a car that does not start and I cannot afford to spend anymore money on it.

 

Faulty fuel pump on the engine??There common for nacking up

 

I suspected the fuel pump too but the mechanic got it going again and I drove it around all day. It was only when I left it overnight that the problem returned??? Would this not suggest the pump is still working?

 

Mate not the same car but on my merc ml I had this exact same problem, luckily it would still start but took ages to get going then fine all day.
Turned out to be worn o rings on the fuel system not retaining pressure and causing the lines to empty overnight.
Replaced all o rings and it's never come back.
Worth a try for £5.

 

How did the guy get it going again?

As above suspect air getting in and fuel draining back overnight.

 

Not sure what the mechanic did to get it started. He just told me it was air locked.

 

I take it the fuel filter is new.

 

No the fuel filter is not new.

 

The answer is obvious really as said, air is getting in somewhere when its sat overnight, allowing pressure to drop, lines to empty etc then when you start it it wont go cause its full of air.

 

I tried earlier to get rid of any air just to see if that is the problem before I call a mechanic but I still it will not start. Here is what I tried, maybe someone can point me in the right direction as I dont know what I'm doing. I removed the 3 pipes from the fuel filter and using a syringe, I filled the filter up with diesel through the inlet pipe (the one coming from the tank). After that I filled the pipe that runs into the engine (the middle of the three pipes). I replaced two of the pipes leaving only the outlet pipe off and turned the engine over a little just to confirm that fuel is coming out. Once I confirmed that fuel was coming out of the filter I replaced the middle pipe and tried to start the car but to no avail. Am I doing something wrong or is the problem just not air?

 

Would a clogged fuel filter cause these symptoms? Thinking about trying a new one.

 

First thing on any diesel really is a good well flowing fuel filter and is overlooked when people start throwing pumps and injectors at cars with probs, especially TDCI Fords!

Once your fuel filter is full I never advise cranking over TDCIs with any fuel pipes open, be it low or hi pressure, as it introduces air in the system. 'cracking off' the high pressure pipes like you can on old skool engines does not work on these.

You really need a hand primer inline with filter> pump to prime the system initially.

But if the guy uses one then it wo'nt run again after being stood overnight, you have other issues as said above.

 

Triumphant Update! Replaced fuel filter this morning and it started first turn of the key!!!! Get In!!!!

 

Always start with the basics!