mk7 tdci injector coding problems

[surfing1975]

yes, i did take it to someone with ids and it would not accept an incorrect 16 digit code. however when we eventually got the codes correct it accepted all of them but van is still in the same condition as when leaving the diesel specialist. So frustrating. Going to install old injectors tomorrow and see if better again. These van are sh**e. 150k and they may as well be scraped. Never had these problems with mk5's and mk'6. joke

[knobby1]

yes, i did take it to someone with ids and it would not accept an incorrect 16 digit code. however when we eventually got the codes correct it accepted all of them but van is still in the same condition as when leaving the diesel specialist. So frustrating. Going to install old injectors tomorrow and see if better again. These van are sh**e. 150k and they may as well be scraped. Never had these problems with mk5's and mk'6. joke

I'd debate they're "shite"...mine runs fine since I have sorted all the gremlins, now it's just a matter of giving it regular servicing/maintenance to keep it that way, less chance of it letting me down. A lot will depend on how they were maintained in their previous life I suspect. Admittedly, everything engine/fuel related has to work well together and they're often easily upset by a seemingly small issue.

There are literally millions of Transits in the UK and Europe...and people only come on this forum when they have a problem and need help, we do our best...people don't often come here to say how well their pride and joy is running. Doesn't matter what make or model of vehicle you have, all of them have "issues".

Lord Knobrot

[surfing1975]

Does anyone know if messing around with programming can damage injectors or pump. cheers all

[bady2016]

1000km. holy cow. best i have ever got was 450 on my mk7 115ps. 380 on this 100ps

Obviously yours are not running well. Even with a 1000kg load in I get well over 900km or ~560miles+.

Lord Knobrot

I've been driving very carefully to get 460. I'll have it remapped after Easter by same guy who coded injectors will ask him what software he used for that.
regarding mileage I've fitted 3.11 diff ratio it has lowered revs when cruising on 6th gear but it is harder to take off this might be a reason why can't get more than 500+miles. will see after re map
RWD takes more fuel than FWD this matters to.

[surfing1975]

so. i removed the injectors from the 100ps van and reinstalled them into the 115ps van and it drove beautifully, no misfiring or, chugging out loads of white smoke. So this should prove that the injectors are ok (i think). I have now reinstalled them back into the 100ps van and obviously it is belching out white smoke and misfiring, so i will drive it straight to diesel specialist in the morning to see if they can rectify. As mentioned before we have now put the correct codes into the ecu using ids but to no avail. So i can only hope that the diesel specialist can undo what ever the hell they have done and restore my van atleast to its none misfiring state. Im not confident for some reason.

Whilst doing the above i did also put the original injectors back into the 100ps van but it was still misfiring although i expected this as we have changed the codes now.

cheers
Does anyone have any idea why my van is knackered from initially inputing incorrect codes on bosch and then re programming scv and pump? please.

thanks

[paul2012]

MK7 injectors

6C1Q-9K546-BC (High flow) fits
2.2 - 115ps, 130/140ps
2.4 - 130/140ps

6C1Q-9K546-AC (Low flow) fits
2.2 - 85ps & 110ps
2.4 - 100ps & 115ps

9C1Q-9K546-BA fits
2.4 - 135/140ps with DPF from 2008 onwards

[knobby1]

I've fitted 3.11 diff ratio

3.11 diff ratio..?? Where did you get this from..?? I thought 3.31 was the lowest available for the RWD..??

Lord Knobrot

[surfing1975]

Nobody??

[knobby1]

Does anyone have any idea why my van is knackered from initially inputing incorrect codes on bosch and then re programming scv and pump? please. thanks

If the injectors are not up to snuff or the codes are incorrect, the learns will fail. If the SCV and/or the PRV are not well, the learns will fail. If the procedure has been completed "succesfully", the engine should run pretty well, I'd suggest the learns have failed in your particular case.

The "learn" procedure is not a programming as such, it's basically a "calibration" of the injectors, pump, SCV and PRV to each other.

Lord Knobrot

[surfing1975]

van went back to diesel specialist this morning and they agreed to re code injectors free of charge as it was not done correctly first time because i gave them the wrong codes. Unfortunately and as expected the van is still surging (not misfiring apparently) and belching white smoke. they have the van booked in to do further diagnostics on Wednesday.
I took van home and connected a clear pipe to the return on the fuel filter ( could not obtain a pipe big enough to connect from the flow off the filter to pump) it is showing a small amount of air on idle by small i mean a bubble every 15 seconds or so. But after revving there are lots of air bubbles, i think this is normal as when doing leak off test there are lots of bubbles.
I then swapped the scv valves from other van again and i did notice that the o-ring had indeed been nipped on installation however this still did not cure problem. Next i swapped the entire fuel filter and housing from other van but still no improvement. Totally at a loss now! don't know what to do next, I am now thinking that if it isn't a problem caused by programming and damaging ecu, it must be internal engine related, ie timing or piston ring.But i am hoping and think that this is not the case, surely its something they did when originally programming wrong codes.

Also swapped air sensor and map sensor again. I did feel on the way home after all this messing the van was driving alot faster although when idling still surging and shaking van.

any thoughts

[surfing1975]

ps they have told me that the rail pressure is good and stable and that they happy the pump,prv and injectors are all ok. They really seem to have no clue but have booked it in for further diagnostics. This has me worried, what can they do that i cannot, maybe i should check timing although they seemed unconvinced that this was worth doing. I ve nearly had enough

[knobby1]

I then swapped the scv valves from other van again and i did notice that the o-ring had indeed been nipped on installation however this still did not cure problem.
any thoughts

You can't just change the SCV without performing the Pump and Pilot learns, she'll usually run like a pig...no two pumps, SCV's, PRV's or injectors are the same as the next, they may look the same... but the SCV inner spring strength and voltage required to move the valve to a certain flow value will be different from one valve to the next, no two pumps will have the same flow and pressure values at the same rpm as another pump etc....hence why Ford use the learn/calibration process to match all the components to each other after one or more of the components has been changed or replaced.

Lord Knobrot

[surfing1975]

Van in again today. Relearned scv and pump. No joy. Mentioned play in flywheel could be confusing cranshaft sensor causing engine to surge. Replacing scv first with a new one just to be sure. If this fails i guess ill be removing the gear box. Or removing van from my life somehow

[surfing1975]

brand new scv and i let them install it and program it . Same same. Going to bench test injectors tomorrow.

[surfing1975]

so injectors have checked out ok, however it is still smoking and idling very erratic. I have connected a clear hose to the outlet of the filter to the pump and there was loads of air being pulled through, so i rigged up a small tank and bypassed filter, the van definitely ran better but still not right. I have now found that disconnecting and reconnecting the high pressure sensor on the rail whilst running (opposite end to the prv) sorts the problem out. I am now going to get the high pressure sensor off the other van and see what happens. If this turns out to be the problem i will be mighty upset that i have given diesel specialist £340 for diddly squat