This is where I'm at

[seamie]

I've been trying to get rid of a knock in my van from I bought the pig.

I had the injectors looked at and apparently they're 100%

I've had the scv and prv changed

Two new fuel pipes fitted

Had a pcm update

New throttle pedal on today to stop the random revs

I checked the injector codes on the head of the injectors and compared them to the ones that showed up in IDS and none of the four matched. So I entered the codes from the injectors into IDS, which were accepted, but I couldn't complete the pilot correction learn with excessive correction factors on cylinder 2 - pilot learn fault code 91 given as the reason why. I changed the injector code in cylinder 2 to the one that was originally in IDS and run the pilot learn again and this time it failed on excessive correction factors on cylinder 4

Last night I noticed the fuel rail pressure acting erratically and today while running the pilot learn I noticed a diesel leak where the new PRV (Fitted 3 weeks ago) enters the fuel rail. Would this be a result of me messing with the correction factors?

I also noticed oil around the seals on cylinder 2 and 4 yesterday so I took off the clamp between the injectors in cylinder 1 & 2 to clean the oil and monitor it (in case it was there from when I had the injectors "looked at") and noticed a bit of play on the injector in cylinder 2, I could lift it up and down a couple of mm easily while number 1 was rock solid. Should there be any play in the injectors?

Heres the injector codes

Original

F0001800000012FA

F0002116192E24D4

F00012F10009001A

F00000F2D5F7F3D3

Codes I read from the head of the injectors

F0001A0000130FF6

F0001700000000E7

F0001C00001014E8

F00000ECEEF3F2F3

Its possible I could misread one or two characters but these two sets of codes are like day and night. What do the codes tell about the injectors?

I was asked to check the codes on the timing cover but unfortunately I can find them.

Sorry for the long post

Any suggestions on any of the problems welcome

Thanks for reading

[v8dave]

The injector codes can only be the numbers 0-9 and the letters A-F, additionally IDS seems to know that the values can only be in certain ranges and will reject out of range codes when their input.

The injectors should be rock solid in the head. Are the clamps up the right way ?

I don't know the pilot fault codes and have not managed to find any info on the web to help.
Have you done a leak off test ? Excessive leak off will cause pilot learn failure.

[seamie]

The injectors should be rock solid in the head. Are the clamps up the right way ?.

When I took the clamp off the counter sunk hole was to the bottom which I found odd but, as thats the way it came off and the way the other one was fitted, it went back on the same way. Is this the right way?

No leak off test done

[seamie]

Regarding the injectors being rock solid - I bought 4 copper washers from ford (€14 each )today. Are they tricky to fit?

[seamie]

Fixed the leak between the prv and the fuel rail. Turns out the old washer was still on the fuel rail.

[v8dave]

The injectors should be rock solid in the head. Are the clamps up the right way ?.

When I took the clamp off the counter sunk hole was to the bottom which I found odd but, as thats the way it came off and the way the other one was fitted, it went back on the same way. Is this the right way?

No leak off test done

I think that is upside down, it will touch the cam cover which prevents the injector from being clamped properly.
Have a look here viewtopic.php?f=5&t=100735
Don't forget you should always use new clamp bolts as they stretch when installed and are not designed to stretch twice.

The copper washers should be easy to fit, make sure you get any old ones out of the hole so that you have clean alloy showing at the bottom of the hole.


I found a 1/4 hex screwdriver bit extension perfect for getting them out if they did not come out on the injector.

[seamie]

Thanks for your help Dave, much appreciated

I managed to pull the injectors and swap the washers. They were worn and pitted with injector 4 (cylinder 2) being the worst of the four. The tapping is still there but nowhere near as bad, perhaps two new stretch bolts might help.

My mistake regarding the clamps they were in he correct way

In your picture below you say the bottom should be clean alloy but on mine all I can see is black oil, something to be worried about?

[v8dave]

In your picture below you say the bottom should be clean alloy but on mine all I can see is black oil, something to be worried about?

If there is only oil in the hole it's probably ok but you really need to be certain there is no carbon build up from where they've been leaking otherwise the new copper washers don't seal.

[seamie]

Tbh I think it was just oil but I guess I'll have to pop one off tomorrow afternoon to be certain.

[seamie]

Do the stretch bolts have to be torqued or can I just tighten them up?

[seamie]

I have another fault that I forgot to add to the opening post.

PTO switch enable

Anyone know what this is? I've read countless threads that go absolutely nowhere

[v8dave]

Stretch bolts are 6nm plus 180 degrees
You have to use new ones or they will not tighten correctly. reused ones either break or come loose.

Unless you have a pto you can ignore the error code, if it keeps reappearing a pcm update will usually get rid of the problem.

[seamie]

Cheers Dave, I plan on getting new stretch bolts tomorrow and hopefully the lend of a torque wrench.

The PTO refers to power take off

[loot]

Go into service functions and look for rpm limiting, go into it and set it to none/zero or off (i forget Lol but turn it off anyway )
That'll get rid of that code

With injector codes as Dave said, you can enter a wrong number/letter that can be accepted and green but if it is wrong i think that will flag that code so you really need to try and get the right codes, that said you seem to have plenty in your plate with the loose injectors and leaky prv Lol

[seamie]

Thanks Loot I'll give that a try shortly.

The prv is now fixed . The copper washer on injector 4 was battered so hopefully the new one will sort out my jumping injectors

I have the injectors out so the codes have been tripled checked