2005 125ps TDCI HESITATION/SMOKE & ROUGH AT STARTUP ??HELP??

[andybuk2008]

Hi all, First can I say I love the site, Wish my first post was on a happy note.

Its getting me down as I love my van.

I would really appreciate you advice.

I have a 2005 swb 125ps tdci. 90,000 miles & full service history.

All of a sudden it has started making a knocking/tapping or rough sound on cold startup. And sometimes a weird noise from airbox area on start up like a chugging noise.

Also when I accelerate it seems to hesitate, then blow out black smoke and pick up again.

Sometimes when I turn engine off I hear a noise from under bonnet like something de-pressurising from around clutch resivoir.

It has been serviced with oem ford parts. oil, all filters inc correct tdci fuel filter and still no joy. Although they did put a tad bit too much oil in which I had to drain out to get it to correct level.

Filled tank and put injector cleaner in but no joy.

I have also tried cracking injectors to see if any air in lines but still no joy.

No ecu light on and when it was scanned it only showed up lamp generator circuit which he cleared for me and it has not come back on since.

If you can help me in any way I would very gratefull

Thanks in advance

[madmark]

i had this abit with me ,you put your foot down it holds back then puffs out smoke
i have disconected the egr valve and put a screw in the end of the pipe that goes to it ,this stops it smokeng and it runs alot better ,so try this first and see ,but as for the bad lumpy noisey cold start i am not shure about that!

[andybuk2008]

Update.

I took it to ford yesterday night and it is 2 days out of warranty so they said they would have to contact ford uk to see if they will give goodwill on the job.

Anyhow I left it there last night so they could see it from cold.

They top engineer said that the egr was working fine and problem may be with injectors he thinks re-programming them will sort this out. He said as they are out of synch, the engine retards timing and is causing my noisey start-up and hessitation.

Also he found a small oil leak from the pipe from egr which was spraying fine oil mist over gearbox. He put new clip on..

He also said I might require a updated aux belt as mine has some play in it and making noise also.

I have not had van back today as they said they will need to sort out warranty work goodwill with ford uk. I gave them my service book to send off which has full service every 15k so I will be very annoyed if they refuse to cover this only a few days over warranty exp.



Has anybody else had issues with injectors needing re-coding and did it help.?????

What would a small leak in egr pipe cause also but I doubt this is causing all the problems.

[andybuk2008]

Just been quoted £220 for injector re-code from FORD

They want 70+vat before I can even have the van back without doing any work.

Does anybody know if the re-code can be done elsewhere?

With a aux belt fitted also they said it would be £364.42 total

And is only a few days out of warranty period!!!! No Goodwill at all and I have full service history......

Any advice appreciated

[madmark]

i would be onto customer services that is bad news!

[coconut]

Whats the reason behind them refusing goodwill

Had a very similar thing on monday, van was 3 days out of warranty on 82k, needed DMF etc, bloke was offered 30% goodwill originally, he got on the phone to customer service (or lack of customer service should I say ) kicked off at them, ended up will 100% goodwill, so its definitley worth giving them a call

£220 seems very steep for the injector correction factors to be done, book time is only 0.1hrs per injector or 0.2hrs for all 4 injectors to be coded (once IDS is connected) so I think there having a laugh there

The aux belt noisy is a common known fault, im presumming you have A/C, if so then I would guess you need TSB 18/2005 doing, that involves replacing the aux belt, aux belt tensioner and the crankshaft pulley/damper (which is why the high price quoted), but again try customer services as its a known fault so you should get goodwill on it

[darkbluevanman]

They want 70+vat before I can even have the van back without doing any work.!!

I'd go back down ask for my van, if they refuse phone the police... theft/blackmail etc then try a different garage or as mentioned customer services saying your next van will not be a Transit!

[coconut]

They want 70+vat before I can even have the van back without doing any work.!!

I'd go back down ask for my van, if they refuse phone the police... theft/blackmail etc then try a different garage or as mentioned customer services saying your next van will not be a Transit!

Standard 1 hours labour for initial investigation/IDS checks, should have been OK'd before any work carried out/booking van in/taking van into dealership

[andybuk2008]

They offered 30% goodwill but that is only on parts or work done.

Reguardless they want £70+vat for a diagnostic.

But I told them that I had the fault codes read the day before at local garage and none were found.

So all they have done is started it up and had a quick listen.

I will go in the morning and play my mouth and quote that the time of recode is 0.2 hours by the book.

Apart from that I will try and get them done elsewhere.

I take it the numbers on the injectors just have to be reprogrammed back in to the ecu?

[sle1r]

Hi,

Can't wait to see whether it fixes it...my 137ps 2005 jumbo has exactly the same hesitation so will watch this thread closely, just want to see where / how it can be done for less than our local stealer.

Good luck.

[Frag]

Unless the van has had injectors previously (which weren`t coded) i doubt they will need re-coding or that it will cure anything....

Unless someone has mixed them up from original cylinders ?

You`re very lucky if you gotto 90k without having injector "issues".
A leak off test would be my first diagnosis,shows faulty injectors,worst first.
Only problem being when changing worst one,usually other/s get worse or fail as a matter of time.

Knocking & clattering liked with noise from airbox area point more to a valve train/rocker issue.

Unclip air filter at front & lift it slightly,start it from cold & listen while fault is on if you get a loud "popping" noise you have valve/timing issues i`m afraid.....

Noise round servo sounds like either a vac leak/poss pipes across engine as they rub thru.
check all of those thinner rubber ones for chafing/holes & kinks also....

If you have aircon (guessing so from pulley belt isssue) this also makes that noise,its normal....

[andybuk2008]

I was going to hire a leak off test kit for £15 and do this myself.

This would tell me if any are leaking and was told anything more than 10% difference between bottles would need closer inspection on the one that has the most in.

Do you know where I can possibly get a set of injectors for a decent price or have mine recon'd.

Part number etc?

If the fuel pressure was low due to one injector leaking off or over fueling the engine would this cause the engine timing to change as it sees a drop in fuel or pressure or more fuel added.

As the tech at ford said 99% sure after a re-code it would be fine. And he said as the injectors might have gone out of tollerence and firing incorrect that this would retard timing and cause rough sounds from the engine bay and less performance.

Bloody Van. Heres me thinking the tdci engines are a all round better engine. My 100ps tddi never had any issues even with over 135k on the clock.

[Frag]

Bloody Van. Heres me thinking the tdci engines are a all round better engine. My 100ps tddi never had any issues even with over 135k on the clock.

T.D.C.I`s too temperemental,good when they are right but i`d stick with 100ps all day long.
Prob better to have a 100ps re-mapped if you need more poke with reliability......

[darkbluevanman]

They want 70+vat before I can even have the van back without doing any work.!!

I'd go back down ask for my van, if they refuse phone the police... theft/blackmail etc then try a different garage or as mentioned customer services saying your next van will not be a Transit!

Standard 1 hours labour for initial investigation/IDS checks, should have been OK'd before any work carried out/booking van in/taking van into dealership

countries had it.... had a guy wanting something laser cutting today, did mention that the machine was nearly half a million quid and he'd have to get a price from the office... helped him out by letting him use our 2K chomper for free.... nice folks us if only the world was the same. Hell, I even stopped and jump started some pikeys (obvoiuosly didn't know they were pikeys) no big worry... there were only 2 of 'em , wouldn't start '04 fwd tranny, they kept saying water in the fuel, so dropped one of 'em off up the road, told him I didn't live far away... but he already knew LOL Friend for life ;0

[mainroaduk]

Just been quoted £220 for injector re-code from FORD

They want 70+vat before I can even have the van back without doing any work.

Does anybody know if the re-code can be done elsewhere?

With a aux belt fitted also they said it would be £364.42 total

And is only a few days out of warranty period!!!! No Goodwill at all and I have full service history......

Any advice appreciated

Injectors can be coded elsewhere, I had mine done at a local independant garage. Unlikely they`d ave lost they code for know reason though, unless they are knackered or you have another electrical fault. The ford part number for mine was F1439473(2003 van though).
Most diesel speacialist can do leak and pulse tests, I had mine done for about 70 for 4, turns out the test was wrong tough! Some will offset the price of the test against new injectors if you need them, make sure you haggle for this before you hand them over. The injectors are about £650 from ford, and they seemed to average about £120 each for recon ones, this is exchange though, and they have a heavy surcharge on them so its best to take your old ones in if you buy them. Where abouts are you? If you not too far away I can give you some local numbers of places you might get sorted.
Hope you get it sorted soon