Non starting with high fuel pressure

[Solowanderer]

Hi everyone, second only post - first was just to say hello.
Transit is a 2004 2.4 tdci rwd.
I was returning home with a ridiculously heavy load of hardwood firewood and had to climb a humongous hill. Was in 2nd gear with high revs and just as I reached the summit she cut out and I got the dreaded winking orange glow plug lamp. That was the last time she ran. Had to get the RACV to tow me home.
DTC’s using Forscan are:
U1262 - SCP data link fault
P0191 - FRP sensor range/performance
Fuel rail pressure is showing a massive 72,000kpa when cranked, compared to a desired 30,000kpa, before slowly going down after cranking - which I’m thinking isn’t good. I shamefully replaced the SCV or FPV (or whatever it’s called) with a naughty corner Chinese copy but still got exactly the same readings. Haven’t done leak off but did take off the return pipe and cranked her over but didly squat came out. She fires on ‘Start ya b*****d’ (it’s written on the can!) but won’t start.
I really am quite attached to the old girl and have nightmares as to what would happen to her if she was sent to China so any help or suggestions would be warmly appreciated.

[DanMK7uk]

Welcome, Can you confirm the year of the van ? 2004 you say.

[Solowanderer]

Hi Dan,
Yes I believe it’s a 2004
Thanks for responding

[knobby1]

Hi everyone, second only post - first was just to say hello.
Transit is a 2004 2.4 tdci rwd.
I was returning home with a ridiculously heavy load of hardwood firewood and had to climb a humongous hill. Was in 2nd gear with high revs and just as I reached the summit she cut out and I got the dreaded winking orange glow plug lamp. That was the last time she ran. Had to get the RACV to tow me home.
DTC’s using Forscan are:
U1262 - SCP data link fault
P0191 - FRP sensor range/performance
Fuel rail pressure is showing a massive 72,000kpa when cranked, compared to a desired 30,000kpa, before slowly going down after cranking - which I’m thinking isn’t good. I shamefully replaced the SCV or FPV (or whatever it’s called) with a naughty corner Chinese copy but still got exactly the same readings. Haven’t done leak off but did take off the return pipe and cranked her over but didly squat came out. She fires on ‘Start ya b*****d’ (it’s written on the can!) but won’t start.
I really am quite attached to the old girl and have nightmares as to what would happen to her if she was sent to China so any help or suggestions would be warmly appreciated.

The Mk6 TDCi's are well known for having a fragile fuel pump and fuel system in general...Pop the fuel filter off and cut it open....check for metal particles, if so...your pump is done for and has probably take the injectors with it.

Lord Knobrot

[DanMK7uk]

Yes, was my first thought to as knobby says.

Unfortunately they are quite common to go.

[Solowanderer]

Will do, I’m guessing I use a magnet.
Just wondering that when pumps go, can they increase the fuel pressure?

[knobby1]

Will do, I’m guessing I use a magnet.
Just wondering that when pumps go, can they increase the fuel pressure?

If the metal particles find their way to the metering valve, (SCV for want of a better word), yes, it can indeed cause the valve to stick open causing high fuel pressures.

These metal particles can also find their way to the injectors and cause all sorts of drama.....they can find their way back to the tank via the return lines and contaminate the tank and all the lines too.

Lord Knobrot

[Solowanderer]

Well I’ve cut open the fuel filter and no sign of any metal filings. I guess that’s no guarantee that the pump isn’t shot. I’m perplexed as to why I’m still getting such high pressure on crank, especially as I have replaced the control valve on the back of the pump and still get the same readings. I’ve read on the forum that the fuel pressure sensor on the back of the rail almost never is faulty but ordered a new one just in case, as I’m drinking at the Last Hope Hotel.

[knobby1]

Well I’ve cut open the fuel filter and no sign of any metal filings. I guess that’s no guarantee that the pump isn’t shot. I’m perplexed as to why I’m still getting such high pressure on crank, especially as I have replaced the control valve on the back of the pump and still get the same readings. I’ve read on the forum that the fuel pressure sensor on the back of the rail almost never is faulty but ordered a new one just in case, as I’m drinking at the Last Hope Hotel.

Mk6 TDCi doesn't have a "sensor" on the fuel rail..! That's a Mk7 thing.

Was the new control valve a genuine Delphi item or just an ebay special..??

Lord Knobrot

[andz327]

Hi everyone, second only post - first was just to say hello.
Transit is a 2004 2.4 tdci rwd.
I was returning home with a ridiculously heavy load of hardwood firewood and had to climb a humongous hill. Was in 2nd gear with high revs and just as I reached the summit she cut out and I got the dreaded winking orange glow plug lamp. That was the last time she ran. Had to get the RACV to tow me home.
DTC’s using Forscan are:
U1262 - SCP data link fault
P0191 - FRP sensor range/performance
Fuel rail pressure is showing a massive 72,000kpa when cranked, compared to a desired 30,000kpa, before slowly going down after cranking - which I’m thinking isn’t good. I shamefully replaced the SCV or FPV (or whatever it’s called) with a naughty corner Chinese copy but still got exactly the same readings. Haven’t done leak off but did take off the return pipe and cranked her over but didly squat came out. She fires on ‘Start ya b*****d’ (it’s written on the can!) but won’t start.
I really am quite attached to the old girl and have nightmares as to what would happen to her if she was sent to China so any help or suggestions would be warmly appreciated.

Well I’ve cut open the fuel filter and no sign of any metal filings. I guess that’s no guarantee that the pump isn’t shot. I’m perplexed as to why I’m still getting such high pressure on crank, especially as I have replaced the control valve on the back of the pump and still get the same readings. I’ve read on the forum that the fuel pressure sensor on the back of the rail almost never is faulty but ordered a new one just in case, as I’m drinking at the Last Hope Hotel.

Mk6 TDCi doesn't have a "sensor" on the fuel rail..! That's a Mk7 thing.

Was the new control valve a genuine Delphi item or just an ebay special..??

Lord Knobrot

Chineseium

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[Solowanderer]

I’m confused. There is definitely a fuel pressure sensor at the front of the rail, or at least that what I thought it was. It’s 3 pin and from what I understand it’s 5v positive, a negative, and a sender voltage (.5v at no pressure), though I might be very wrong.
Unfortunately the replacement control valve whatever-it’s-called at the back of the pump (which was really hard to replace) is from eBay and cost $70 so I’m assuming it’s not denso.
However, having replaced it, I’m getting identical readings.
I know I’m clutching at straws here and should be using genuine parts, but I’m on a shoestring budget.

[Solowanderer]

Sorry, not denso - I meant Delphi, as in Pytho or this forum

[Solowanderer]

Chineseium?
The part definitely, as are many.

Wisdom and advice on this forum - infinitely more Greek Oracle.

[knobby1]

I’m confused. There is definitely a fuel pressure sensor at the front of the rail, or at least that what I thought it was. It’s 3 pin and from what I understand it’s 5v positive, a negative, and a sender voltage (.5v at no pressure), though I might be very wrong.
Unfortunately the replacement control valve whatever-it’s-called at the back of the pump (which was really hard to replace) is from eBay and cost $70 so I’m assuming it’s not denso.
However, having replaced it, I’m getting identical readings.
I know I’m clutching at straws here and should be using genuine parts, but I’m on a shoestring budget.

Below is the fuel rail for a Mk6 TDCi, can you show me where the sensor is located..??

https://www.catcar.info/ford/?lang=en&l ... I3Mg%3D%3D

Lord Knobrot

[andz327]

I’m confused. There is definitely a fuel pressure sensor at the front of the rail, or at least that what I thought it was. It’s 3 pin and from what I understand it’s 5v positive, a negative, and a sender voltage (.5v at no pressure), though I might be very wrong.
Unfortunately the replacement control valve whatever-it’s-called at the back of the pump (which was really hard to replace) is from eBay and cost $70 so I’m assuming it’s not denso.
However, having replaced it, I’m getting identical readings.
I know I’m clutching at straws here and should be using genuine parts, but I’m on a shoestring budget.

Below is the fuel rail for a Mk6 TDCi, can you show me where the sensor is located..??

https://www.catcar.info/ford/?lang=en&l ... I3Mg%3D%3D

Lord Knobrot

What is this part that isn't listed ma Laird ??

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