Hesitating Smiley Mk5 2.5D 270K any ideas???

[97transit2.5D]

Hi when I accelerate the 97 smiley it is hesitating

it has previously 30k before had all new Stanedine injectors replaced so don't suspect those...and does not blow steam/white smoke...is clear as.starts first time

could be lift pump?? fuel filter?? bosch mech pump???

mechanical brake sticking???

could it be the electronic pedal accelerator...as i know they fail??

putting it out on the forum

cheers Rick

[Jim Archer]

'Torque sleeve piston' sticking - search forum for pics/diagrams - make a note of the order of the thrust shims between spring and piston.

Jim

[gotgcoalman]

As above......................

free /easy inexpensive stuff to check as well.

If it's the Di not the Tdi it's cable operated and might be sticking.

Check fuel lines aren't blocked.

Lift pump (check for flow) messy if you don't put a pipe on the outlet and catch the fuel in a bottle.

When was the filter last changed?

Does it rev freely when not in gear to rule out brakes seized/dragging?

[97transit2.5D]

Hullo

Jim, sorry
I'm a bit light on the jargon your using.(Torque sleeve piston sticking??)

do you think that the problem could be in the injection pump? If so I have hearld that mine is a mechnaical type as opposed to the expensive electronic ones
which when they are faulty your vehicle is not worth repairing.

I drove it yesterday again, and this starts to be obvious (the hesitating) at 2000revs and in thrid gear...it seems you gentlemen know exactly what this could be!

If it's the Di not the Tdi it's cable operated and might be sticking. YES this is the nonturbo 2.5D is that the Di?

Check fuel lines aren't blocked.have not checked

Lift pump (check for flow) messy if you don't put a pipe on the outlet and catch the fuel in a bottle.have not touched the lift pump

When was the filter last changed?diesel filter was installed feb 2005 at 206,000km or 64000km ago

Thanks for any further help.

[97transit2.5D]

Hi there

yep Jim I see you're are talking about...its the injection pump

have found this

viewtopic.php?f=18&t=45777

and this

viewtopic.php?f=4&t=159587&start=0

[97transit2.5D]

hi Chaps

can anyone direct me to the best quality source of new torque sleeves and pistons in the UK, dont seem to be any on ebay.uk
Ford NZ does not supply these any more.

Rick

[vanfox]

Mine was absolutely glued! A lot of people don't know there is a thread in the bottom of the piston you can use to extract it, which I did. Gave it a good cleaning with Farecla G3 compound, all new and shiny, now back running. There's pics of it on here about a month ago. Give it a good clean and try it. Worked for me.

As for your faultering problem, you've highlighted all the items you should check. Blow the tank feed with an airline. After running the engine check for a hiss when you take the filler cap off. Check the vacuum relief valve on the back of the tank, it should rattle. Check the water trap on the bottom of the fuel filter, if still fitted, better still change the filter, 64000 ks is a long time to keep a filter.

[97transit2.5D]

thanks for the heads up on cleaning the piston...with Farecla compund......have since found out that the torque sleeve is the most likely to need replacing than the piston and as you have done clean it up.

thread in the bottom of the piston you can use to extract it,--> will look for it!

Have PM-ed members who had same problems and have said that they never did find a UK or otherwise supplier of bosch pump parts to call on.

Instead they say the refurbishers of Bosch pumps have all the parts or to find a second hand pump.

Surely the refurbishers must get the parts from Bosch or OEM company directly or indirecty ???

[vanfox]

Pics attached.

[97transit2.5D]

wow what a difference...but became of your torque sleeve and what wear was present on it...was an ew one put in??? ..and did you clean gunge underneath at the bottom and how ,,compressed air???

and did you have to remove the whole pump or did you leave it installed in the vehicle???

[vanfox]

I've done them both on and off the engine. This one, the piston and sleeve came out together and needed.....persuading to part. The pump was clean so just polished up the parts and reassembled, away it went !!! Suck it and see, it don't take long to clean and reassemble. Have some cloths around the pump to catch anything falling un-noticed.

[97transit2.5D]

ok....how do you know if the torque sleeve needs replacing? , the pston i understand seldom needs replacing.

Yes, I intend to step up to the mark and do the brave thing and work on it with it installed on the engine...and catch the shims???? that could fall out...and have to watch the order they are in???

do you have a picture of what the shims look like?