Injection pump learning issue (transit 2.2 2007)

[Gilou]

Ford Transit engine 2.2 130HP 2008 FORScan 2.3.63
Hello, After having installed 4 refurbished injectors and a new pump (hopefully genuine) I could recode injectors and start the engine.
Then I launched the pump learning service. Everything whent fine till 46% when the message installation error poped up due to intermitent problem on fuel pressure sensor short circuit to Vbat.
Using FORscan oscilloscope I checked / compared pressure measured VS expected pressure. The pressure signal looks OK, it matches the desired value with a little bit of noise.
Some others experienced the same issue shared on internet but I have not found any happy end with this issue fixed.
Does anyone know what to do in such a case?
Thanks in advance

[knobby1]

Ford Transit engine 2.2 130HP 2008 FORScan 2.3.63
Hello, After having installed 4 refurbished injectors and a new pump (hopefully genuine) I could recode injectors and start the engine.
Then I launched the pump learning service. Everything whent fine till 46% when the message installation error poped up due to intermitent problem on fuel pressure sensor short circuit to Vbat.
Using FORscan oscilloscope I checked / compared pressure measured VS expected pressure. The pressure signal looks OK, it matches the desired value with a little bit of noise.
Some others experienced the same issue shared on internet but I have not found any happy end with this issue fixed.
Does anyone know what to do in such a case?
Thanks in advance

Why was the pump replaced..?? They very rarely, (if ever) fail.

Did the "refurbished" injectors come with their own "new" 16 digit correction factor codes..?? Or did you use the original numbers on the electrical connectors.??

Lord Knobrot

[Gilou]

To Lord Knobrot,
Hi, thanks for your quick answer. The injectors came from WTDiesel with test results and new 16 digits calibration code. I could manage to recode them using Forscan.
I replaced the pump after having found few metal particle in the fuel filter. I cleaned as good as I could the fuel supply circuit and decided to replace the pump. Many Duratork engine produced from 2006 to 2009 broke with defective pump as the root cause. It is of course a signicant amount of money but it stays much lower than a new engine. Total cost remains affordable as long as I am doing all by myself.
By now I am still struggling with the service "pump learning" stoped at 46% still reporting an intermitent failure due with fuel pressure sensor shorted to Vbat.

I will check the wiring of the pressure sensor and monitor the pressure signal physically with an oscilloscope to verify the quality of the signal. I will inform about the outcome. Should you have other ideas please let me know.

[knobby1]

To Lord Knobrot,
Hi, thanks for your quick answer. The injectors came from WTDiesel with test results and new 16 digits calibration code. I could manage to recode them using Forscan.
I replaced the pump after having found few metal particle in the fuel filter. I cleaned as good as I could the fuel supply circuit and decided to replace the pump. Many Duratork engine produced from 2006 to 2009 broke with defective pump as the root cause. It is of course a signicant amount of money but it stays much lower than a new engine. Total cost remains affordable as long as I am doing all by myself.
By now I am still struggling with the service "pump learning" stoped at 46% still reporting an intermitent failure due with fuel pressure sensor shorted to Vbat.

I will check the wiring of the pressure sensor and monitor the pressure signal physically with an oscilloscope to verify the quality of the signal. I will inform about the outcome. Should you have other ideas please let me know.

Fair enough..!

The pressure sensor you speak of...is it the one on the left end of the fuel rail as you look at it..?? If so, they also rarely fail...checking the wiring etc. is a good call.

Lord Knobrot

[Gilou]

I checked the wiring carefully and monitored the output with an oscilloscope. Forscan data and oscilloscope shows the same curve.
I did not find anything wrong. I am now convinced that the issue is somewhere else but the mystery remains...

Any idea will be welcome.

[Gilou]

Here is a short update of my investigations:
Wiring is OK:
- continuity <10 milliohms from sensor to ECU (all pins)
- insulation > 10 MegOhm from wire to wire , wire to ground, wire to Vbat,
Signal quality measure with an oscilloscope:
- Dc voltage at the sensor output= 1.35 V at idle
- AC noise +- 30mV peak
Enenthough the noise level seems to me beeing acceptable I decided to reduce it by inserting a first order filter.
- The noise went down to +- 15 mV peak which is OK in this environment.
Without really believing it, I started again the pump learn service. Unfortunately it failed again at 46% with the same error message.

After conduction all these investigations and reading many posts on the internet reporting the same problem without finding the solution I am thinking about a bug in Forscan or, at least a mistake in the reason of the abortion.

Since the engine is running fine I give up for the moment and stay with a temporary status with the pump learn.
I am stil interested in any new idea...

[Neilanthony2]

Here is a short update of my investigations:
Wiring is OK:
- continuity <10 milliohms from sensor to ECU (all pins)
- insulation > 10 MegOhm from wire to wire , wire to ground, wire to Vbat,
Signal quality measure with an oscilloscope:
- Dc voltage at the sensor output= 1.35 V at idle
- AC noise +- 30mV peak
Enenthough the noise level seems to me beeing acceptable I decided to reduce it by inserting a first order filter.
- The noise went down to +- 15 mV peak which is OK in this environment.
Without really believing it, I started again the pump learn service. Unfortunately it failed again at 46% with the same error message.

After conduction all these investigations and reading many posts on the internet reporting the same problem without finding the solution I am thinking about a bug in Forscan or, at least a mistake in the reason of the abortion.

Since the engine is running fine I give up for the moment and stay with a temporary status with the pump learn.
I am stil interested in any new idea...

Any luck with this Gilou? Having the same issue with my 2007 2.4 and can't get to the bottom of it. Stuck in temp pump learn and fails at 46% stating an intermittent fault with fuel rail pressure sensor short to vbatt. Replaced all the relevant sensors and. Checked wiring to no avail.

[knobby1]

Any luck with this Gilou? Having the same issue with my 2007 2.4 and can't get to the bottom of it. Stuck in temp pump learn and fails at 46% stating an intermittent fault with fuel rail pressure sensor short to vbatt. Replaced all the relevant sensors and. Checked wiring to no avail.

Are "both" of your batteries ok..?? Have you had them properly load tested..??

Sometimes a poorly front battery will throw this fault.

Lord Knobrot (Smithy)

[Neilanthony2]

Thanks for the reply! Haven't load tested the batteries but I do know the module voltage on forscan was reading at 14.3 and the physical battery voltage for both batteries is around 12.7v.

I have a noco so could put it on the front battery and try it again? I've read so many posts about this exact fault and cannot find an answer anywhere! Had suspicions it may be a faulty PCM but again, can't find an answer from anyone who solved the issue!!!