Some fault codes

[knobby1]

All that gunk in the manifold is actually quite normal...its due to a combination of the crap coming from the breather system and the EGR....fitting a catch can in the breather line from the rocker cover will help dramatically, most of the air coming from the EGR is dry exhaust gas.

The split manifold gasket is probably where your "whistle" is coming from.

SCV doesn' care which way "up" it is. As long as it's a genuine Denso/Ford item you should be fine....replacing the PRV on the rear end of the fuel rail is also a good idea. SCV & PRV should normally be replaced as a pair.

Be sure to do the learns after getting it all back together and running.

Lord Knobrot

[Harvy]

Thanks for your input as usual m’lud! I do remember you referencing the ‘oily spooge’ in one of your comments and mentioning that you have a catch can. Do you have any photos of where you installed this and how big it should be to be effective?

Hopefully replacing manifold gaskets will stop the whistle like you suggested. The diesel shop didn’t have a PRV in stock so I thought I would replace the SCV and do the learns on the new SCV and the old PRV while waiting for a new PRV to arrive. It only takes about 10 mins to get the fuel rail out so not too bad, although I know the PRV can be a tight fit! Are your fuel rail bolts the same as mine with the poor clearance and no tool access?

[knobby1]

Thanks for your input as usual m’lud! I do remember you referencing the ‘oily spooge’ in one of your comments and mentioning that you have a catch can. Do you have any photos of where you installed this and how big it should be to be effective?

Hopefully replacing manifold gaskets will stop the whistle like you suggested. The diesel shop didn’t have a PRV in stock so I thought I would replace the SCV and do the learns on the new SCV and the old PRV while waiting for a new PRV to arrive. It only takes about 10 mins to get the fuel rail out so not too bad, although I know the PRV can be a tight fit! Are your fuel rail bolts the same as mine with the poor clearance and no tool access?

I just fitted a generic catch can from ebay, nothing special, mounted it just in front of the power steering pump onto the slam panel... lower end connects to the breather hose coming from the rocker cover, the other end normally goes to the big inlet pipe where the original breather hose goes. Mine actually breaths to atmoshpere and the inlet pipe is now blanked off...so I get absolutely no breather fumes going back into the engine and my manifold and inlet ports are much cleaner as a result. I still have a properly working EGR so I still get exhaust fumes into the inlet, but it's dry fumes and has not been an issue since I fitted the catch can. I actually catches quite a lot of spooge and I need to empty it maybe one every couple of months.

Lord Knobrot

[Harvy]

I just fitted a generic catch can from ebay, nothing special, mounted it just in front of the power steering pump onto the slam panel... lower end connects to the breather hose coming from the rocker cover, the other end normally goes to the big inlet pipe where the original breather hose goes. Mine actually breaths to atmoshpere and the inlet pipe is now blanked off...so I get absolutely no breather fumes going back into the engine and my manifold and inlet ports are much cleaner as a result. I still have a properly working EGR so I still get exhaust fumes into the inlet, but it's dry fumes and has not been an issue since I fitted the catch can. I actually catches quite a lot of spooge and I need to empty it maybe one every couple of months.

Lord Knobrot

Fair enough. I’ll see what eBay has on offer and fit it as you have suggested. I don’t like the idea of that rocker cover air going through the entire intake pipe work from the father to the engine! Will the inter cooler be full of all the same crap as the intake pipe and manifold? If it is then surely it won’t be working effectively. Is there something I can use to clean it out without having to disassemble it all? I think I read somewhere on here about someone spraying something down the intake while the engine was running? Or am I imagining things?

[Harvy]

Yesterday I went into the garage and finished my attempted clean of the inlet manifold. This is it sitting in my improvised petrol bath. The petrol is like ink with all that crap dissolved into it.

IMG_2721.jpeg

The manifold came out much cleaner on the inside, not perfect but satisfactory. So when the new gaskets arrived I fitted them.

IMG_2722.jpeg

So I refitted the manifold and fuel rail etc. I trimmed this bolt down by about 3-4 mm so I can get it back in without it fouling on the inlet manifold. I still had to tighten it using mole grips though!

IMG_2724.jpeg

I fitted this pipe to the hole that it fits into on the back of the housing for this pulley. What is it for? Is it a vacuum pump?

IMG_2707.jpeg

Once I had it all put back together I got it started up, it took about 4-5 tries and it was a bit sputters to start with. I took it for a short drive because when I set off I remembered I hadn’t done the learns! Back home I did the fuel pump learn and that was it. The pilot learn doesn’t apply as I’ve not replaced the injectors. I’ve not replaced the PRV yet either so I’ve not reset the counter on that either.

I took it on a longer drive while recording live data, parked for 5 mins (Dunkin Donuts, Dangerous, Expensive and Delicious all at the same time!) and then drove back home while recording live data again. I would like to tentatively say ‘It’s Fixed!’ It didn’t loose power at any point and it certainly would have before changing the SCV. I hope this is it for this problem…. On to the next! Thanks all for the help so far.

[Colin K]

Yesterday I went into the garage and finished my attempted clean of the inlet manifold. This is it sitting in my improvised petrol bath. The petrol is like ink with all that crap dissolved into it.

IMG_2721.jpeg

The manifold came out much cleaner on the inside, not perfect but satisfactory. So when the new gaskets arrived I fitted them.

IMG_2722.jpeg

So I refitted the manifold and fuel rail etc. I trimmed this bolt down by about 3-4 mm so I can get it back in without it fouling on the inlet manifold. I still had to tighten it using mole grips though!

IMG_2724.jpeg

I fitted this pipe to the hole that it fits into on the back of the housing for this pulley. What is it for? Is it a vacuum pump?

IMG_2707.jpeg

Once I had it all put back together I got it started up, it took about 4-5 tries and it was a bit sputters to start with. I took it for a short drive because when I set off I remembered I hadn’t done the learns! Back home I did the fuel pump learn and that was it. The pilot learn doesn’t apply as I’ve not replaced the injectors. I’ve not replaced the PRV yet either so I’ve not reset the counter on that either.

I took it on a longer drive while recording live data, parked for 5 mins (Dunkin Donuts, Dangerous, Expensive and Delicious all at the same time!) and then drove back home while recording live data again. I would like to tentatively say ‘It’s Fixed!’ It didn’t loose power at any point and it certainly would have before changing the SCV. I hope this is it for this problem…. On to the next! Thanks all for the help so far.

#Oh my goodness so SCV ? Right get one tomorrow. I will strip out the inlet manifold and clean it up. Ooooo actually I have a spare engine here I will get the inlet manifold off that one soaking I cannot get Forscan to complete the pump learns so wonder if the SCV is also interferring with that? The PRV is that the one on the end of thefuel rail I swapped that on mine!


Thanks for the update, Col.

[Harvy]

Well it certainly appears to have fixed my issue. No promises but it seems you have changed most other bits! I’m sure you said that you checked live desired and actual fuel rail pressure during the time that your van was faulting and they matched. Mine didn’t which is what lead to diagnosing the SCV potential sticking. Having said that the problems we are having are literally identical. I would suggest that a faulty SCV would cause a fuel pump learn to fail as its one of the moving parts, sometimes called the metering valve.

[Airthies]

Yesterday I went into the garage and finished my attempted clean of the inlet manifold. This is it sitting in my improvised petrol bath. The petrol is like ink with all that crap dissolved into it.

IMG_2721.jpeg

The manifold came out much cleaner on the inside, not perfect but satisfactory. So when the new gaskets arrived I fitted them.

IMG_2722.jpeg

So I refitted the manifold and fuel rail etc. I trimmed this bolt down by about 3-4 mm so I can get it back in without it fouling on the inlet manifold. I still had to tighten it using mole grips though!

IMG_2724.jpeg

I fitted this pipe to the hole that it fits into on the back of the housing for this pulley. What is it for? Is it a vacuum pump?

IMG_2707.jpeg

Once I had it all put back together I got it started up, it took about 4-5 tries and it was a bit sputters to start with. I took it for a short drive because when I set off I remembered I hadn’t done the learns! Back home I did the fuel pump learn and that was it. The pilot learn doesn’t apply as I’ve not replaced the injectors. I’ve not replaced the PRV yet either so I’ve not reset the counter on that either.

I took it on a longer drive while recording live data, parked for 5 mins (Dunkin Donuts, Dangerous, Expensive and Delicious all at the same time!) and then drove back home while recording live data again. I would like to tentatively say ‘It’s Fixed!’ It didn’t loose power at any point and it certainly would have before changing the SCV. I hope this is it for this problem…. On to the next! Thanks all for the help so far.

#Oh my goodness so SCV ? Right get one tomorrow. I will strip out the inlet manifold and clean it up. Ooooo actually I have a spare engine here I will get the inlet manifold off that one soaking I cannot get Forscan to complete the pump learns so wonder if the SCV is also interferring with that? The PRV is that the one on the end of thefuel rail I swapped that on mine!


Thanks for the update, Col.

Possible but could be injectors out of spec causing your learn failure.
Before stripping anything do an injector leak of test.