MK6 TDCI - Metal Swarf in Injectors

[grogan197]

I had a recent injector problem that was causing a loud knock on acceleration. I went to a garage and they said it was doe to the last batch of injectors not having new c2i code generated when they were refurbished and I should replace the whole set. It seemed a bit drastic as it had been running OK for a year, anyway I bought 2 refurbed injectors and took 2 out to be tested. In the meantime I took the van on a good drive (150 miles) and all was good, engine sounded fine. I got the injectors back from testing and one had failed with no injection under 300bar, the other was fine.

I just took the bad one to bits hoping to find nothing but found 3 strands of metal swarf. What's the likely culprit? I'm guessing it's time for a new high pressure fuel pump

The engine and current fuel pump are from a 2002 mondeo as I had an engine swap a couple of years ago so not sure if the mondeo used slightly different pumps to the transit.

[ned]

Oh dear it sounds like the HP side of the pump is breaking up, have a look on PF Jones website, they have new and reman pumps and injectors, they are very helpful and will answer any questions.

A 2002 engine will be one of the early tdci's like mine which were put in the transit first and then the Mondeo, if your injectors have the longer nozzles then I would guess its the same engine as the transit, if that makes sense. N

[grogan197]

Yeah the injectors are the transit ones. I changed them over from the slightly lower output ones that came with the mondeo engine. I recently read something about the early mondeo pumps being prone to chewing up seals, not sure if it's the same for the transit pumps or when they changed them. Guess I'l have to look at a reman pump. Is there anyway of confirming if it's the pump? Do I need to cut the fuel filter open to check in there for swarf?

[grogan197]

Just checked ford Ecat and the part number for the one from the mondeo currently fitted to mine is 1379365 but it looks like the original would have been a 1379366. They both come up that they were fitted to mondeos and transits and show the same years so not sure when the pump was superseded.

[ned]

If you remove the fuel filter and using a clean glass bowl drain the fuel out the drain plug I think you will see the swarf in there or as you say cut the filter open, if it is the pump that's gone tits up you'll need a new fuel filter anyway along with a fuel system clean and new injectors.

Reman injectors at pf jones are 120 sovs with 30 sovs back for your old ones (90 sovs in the end each) I think the pump is 300 sovs with 50 sovs back for your old one but they may have gone up slightly.

I don't think the pumps changed as I got an IMV off a '05 130 mondeo to test on mine when I was having problems and the pumps looked identical to my pump. N

[ned]

The pump is just a dumb pump there to keep the pressure up in the rail, the IMV operates to allow the fuel up when the injectors demand more fuel. N

[grogan197]

I'm hoping the current injectors will be OK to keep as they aren't playing up yet. I might open them up for a clean though just to be doubly sure there's no swarf in there. Sounds like a right ball ache cleaning out the whole fuel system. sh*t like this always seems to happen when you have a full tank of fuel too

[ned]

Aye its a bit of a ballache cleaning the whole fuel system but if the pump has gone any traces of metal filings could kill a new pump and take the injectors with it, you might be lucky and caught it just in time.

Out of curiosity was the injector you opened one that had been remaned or not, I'm thinking if its a remaned one it might just not have been cleaned fully. N

[grogan197]

It was remanufactured but it had been fitted for a year. I'm not sure if I'll be able to but i'm thinking if I get a magnet on a length of fishing line I could check if there is any swarf in the fuel tank. It'd save me checking in the fuel filter then.

[ned]

You could put a glass under the filter and open the water drain valve.

Its strange how the other injector passed the test so in theory clear and that one failed an has a few strands of filings in.

One would have thought if the pump was starting to fail you would have had running problems and limp mode I'm wondering if the few strands came from the test place. N

[grogan197]

Yeah it would be nice if that was the case. They were a pucker delphi place so they should know there stuff. But they also said it wasn't injecting at 300 bar which is roughly the FRP at idle and the van was running fine at idle.

That's a good idea opening up the water run off. I'll give that a go now. I had a go with the magnet but it seems like it's going to be a right hassle to get it into the fuel tank.

[ned]

I hope it is just the injector that's faulty and not the pump I was driving around for 4 years with duff injectors and now its running like a dream I drain fuel out of the filter water drain once a month just to keep my eye on things and remove any water that might be in there. N

[grogan197]

I opened the water drain and there was no swarf in the diesel drained from there. I then took off the fuel filter and drained it into a container. I didn't cut it open as I haven't a replacement yet. The diesel that came out was pretty clean but there were maybe half a dozen small black flecks in there that responded to a magnet. Not sure if it's normal to get the odd bit of swarf or if any means the pump is breaking up.

I think I'll stump up the cash for a refurb pump to be on the safe side, it sounds like they are a bit of a ticking bomb anyway and after spending out on refurb injectors the last thing I want is to be buying a new set again.

[ned]

https://www.pfjones.co.uk/ford-transit- ... a130a.html


https://www.pfjones.co.uk/ford-transit- ... a130a.html

https://www.pfjones.co.uk/ford-transit- ... a130b.html


It says engine code puma but I think that might be a mistake, a quick email or phone call will confirm the correct one, they are very helpful I'm pretty sure the 'puma' was mk7 and 'FIFA' mk6. N

[grogan197]

Cheers Ned, I've actually just ordered one from them. I got it off their ebay listing, the pump was £300 but £60 cashback for the old one which seems pretty reasonable.

Hopefully I'll be able to get it fitted this week.