Transit 2.2 fwd mk7 help please

[Frag]

I don’t understand how there’s low fuel pressure in the fuel rail but the prv is still opening and letting fuel back into the leak-off pipe, I thought the prv would only open if there was too much fuel in the fuel rail to relieve the pressure? Or I’m I completely wrong?

Thanks

That PRV is no good.

You should not be getting any fuel out of it,
In fact,you should be able to disconnect the leak off pipe connection to it (then plug that pipe to stop air ingress)
and rev the van to full throttle with no fuel from end of rail / PRV.

Replace that PRV with genuine a Ford one,nothing else as everyone has said…
Make sure the sealing copper washer is replaced,(and there isn’t an old one in there)
Torque it to correct spec
You can replace them on a FWD without removing the rail.
You should be getting 230 bar at tickover,no more than 30 bar +/- deviation

[Micktransitman]

Thanks frag I thought as much well I ordered a new one from ford and fitted it I still have air in the fuel, iv made up two clear pipes and for now deleted the fuel filter housing so I can see which direction the air is going and it’s coming from from the return side non enters the system but air bubble flow through the return so this is what I’ve been up too,

I’ve removed the recon injectors and put the original ones back in which I saved there codes when I removed them,

I’ve took every metal pipe off inspected the hell out of them and when I’ve put them back on I’ve used lock tight just if any where pulling air in it would stop it or change the amount of air.

I’ve reused my old fuel rail with the new prv.

I’ve used the brand new leak ford leak off pipes and the old original ones ever time changing the o’ring’s and even tried the blue type ones which seem finer then the green ones.

I’ve even changed the fuel pump

Every part of the fuel system as been changed and then changed back to the original and the problem still persists!!

If there’s any good mobile mechanic specialising in transit in the north east, uk please let me know I’ll take any help…..please someone come show me what I’ve done wrong

[metalworker0]

At this stage i would be disconnecting the pipe work and , maybe pressurising it up ..with and airline, start low perhaps 5 psi .. or buy a smoke tester .. that makes its on air .. like so

https://www.ebay.co.uk/itm/147180678709?

Says in the description, he does not supply the fluid that makes smoke .. i know from sources that it is "baby oil " so don't worry about that

The smoke test method is probably the route a garage would take when all the options have run out.

It's a tool .. that is relatively cheap £36.95 - pocket money. years ago they would have been hundreds of pounds.

all the best.mark

[Micktransitman]

Hi mark thanks for the reply, if you read back thought my post you’ll see I’ve done that already and can’t pin point where the air is being introduced

Thanks mick

[Micktransitman]

Dose anyone know if I can do a software update with forscan? Or will I need ids?

Thanks mick

[metalworker0]

Well when threads go on for a whole year, i forget, i cant think of anything else to suggest, why would a mobile mech have any more clue than you.

i don't know ..i'm not keen to read the whole lot again

so will just suggest some things -- sorry if already suggested
. The pick up in the tank could be cut, split etc, tank needs to be dropped to check this if a van or bus or camper .. not so sure about a chassis cab.

all the best.mark

[knobby1]

Dose anyone know if I can do a software update with forscan? Or will I need ids?

Thanks mick

As far as I'm aware, Forscan cannot do the firmware/software update, IDS can, or at least it used to be able to...however, the file you need is now near impossible to get for us mere mortals. You need the particular file for your exact vehicle...sometimes the software file part number is on a sticker in one of the door-shuts.

You "might" be able to find the particular file you're after here...you need to register to download though... https://www.mod-files.com/original-file ... sit/_/_/1/

Why do you want to do the software update?? All it does on the Euro-4 machines is introduce "anti-stall", deals with the spurious WIF (Water in Fuel) warnings and one or two other minor changes. It has nothing to do with fuel metering etc.

Lord Knobrot (Smithy)

[Micktransitman]

Thanks mark and Knobrot, I would like a mobile mechanic or hardcore transit fanatic for a fresh set of eyes and ideas and I’d like it fixed to be honest lol

every part to do with the fuel system has been changed and yet the problem never changes I never get more or less air in the fuel return line, so I was wondering if it was firmware / software issue that’s all….

The two thing’s I haven’t changed are the tank and crankshaft sensor as I’ve been told non of the would affect air being in the return line, but what’s more puzzling is if you apply positive or negative pressure to the system via the fuel feed or the return lines the positive or negative pressure / vacuum never drops which is making me think it must be something mechanical.

Thanks mick

[knobby1]

Thanks mark and Knobrot, I would like a mobile mechanic or hardcore transit fanatic for a fresh set of eyes and ideas and I’d like it fixed to be honest lol

every part to do with the fuel system has been changed and yet the problem never changes I never get more or less air in the fuel return line, so I was wondering if it was firmware / software issue that’s all….

The two thing’s I haven’t changed are the tank and crankshaft sensor as I’ve been told non of the would affect air being in the return line, but what’s more puzzling is if you apply positive or negative pressure to the system via the fuel feed or the return lines the positive or negative pressure / vacuum never drops which is making me think it must be something mechanical.

Thanks mick

Are you talking about the little bubble in the clear/opaque fuel line which connects from the fuel pump to the filter head..?? If so, I don't think I've seen one without an air bubble in them..!

Have you done the learns again since fitting the new PRV..??

Lord Knobrot (Smithy)

[Micktransitman]

Thanks Lord Knobrot, No I’ve made up two clear pipes my self with the correct size fitting so I could delete the filer head completely for now while I narrow this down, they just bypass the filer by plugging the feed line directly to the fuel tank, same with the return, it was just so I could see which way the air is going, no air enters the system but air leaves through the return lines, the more you rev the engine the worse it gets.

Yeah I always do learns fella

Thanks mick

[andz327]

so you can see some air in the pipe......is the van having problems due to this ?????

if your having problems have you changed the clear pipe? if rubber coolant hoses not secured or routed properly they can rub through the hard plastic fuel pipe and cause tiny pin hole at first which can cause intermittent faults due to the coolant hose actually blocking the rub through , and you don't see fuel leaking either, first discovered it on my own van but have sorted another two vans with same problem , close inspection required

[Micktransitman]

Thanks andz327, no there’s no air in the clear opaque feed pipe, the air is only on the return side, like I said I’ve made up two pipes bridging the fuel filter housing so I can rule it out completely, the engine was hot when I took the pictures aswell

Thanks mick

[Micktransitman]

And it doesn’t matter if the pipes I made up where on or not because if I put the fuel feed into a can of diesel and the return pipe into a glass jar with diesel I still get air bubbles on the return side, while the feed pipe has no air entering the system, the result is the same.

I’ve honestly changed every part at least 3x’s 1x being the original van part, 1x being new genuine ford, 1x being an old part of my old engine or a scrap yard part just so see the anying changes but nothing ever dose, I always get the same amount of air no matter part I fit or to where.

[metalworker0]

https://forums.tdiclub.com/index.php?th ... al.476887/

One poster there says its normal for the decrease in pressure after it has left the high pressure side for the bubbles to grow.
so
i put this into google

size of 1 mm air bubble breaking the surface from 10000 mts down

which just so happens is the lowest range ta diesel pump works at - 1000 atm

answer was 10mm

https://www.google.com/search?q=size+of ... 0+mts+down

and .. don't want to start an argument .. but what happens to all that froth that diesel makes when you fill the tank .. and start engine before it's calmed down

so 1mm bubble (froth) enters pump, gets compressed .. ends up 0.1mm bubble and expands back to 1mm .. if the calculations do the same .

all the best.mark

[Micktransitman]

Hi mark, it’s not just a little bit of air it’s a constant flow of bubbles and when you connect the fuel filter back up it pulls that air into the feed pipe and cuts the van out so this can’t be normal, when you rev the van to 3000 the fuel that is returning disappears as the revs calm down the fuel returns full of air….

Thanks mick