Transit mk7 knock under load

[Hewzey]

Hi hope someone can help please, have a knock when warm and get over 2000 revs under medium load in fifth and sixth gear
I had brand new injectors, ford prv and scv plus leak off o-rings changed, new updated injector clamps and bolts all done to spec and head seats recut when new injectors fitted, corrections done and counters reset and pump and inj learn all successfully plus a pcm update and egr blank and delete and though she seems to drive ok still getting what seems to be a high pitched knock when warm. The van also surges five times every morning from cold start since work been carried out but idles fine after and throughout the day. Could this be a sensor issue although I have no fault codes except for p251a which I have been told doesn't affect running just wasn't cleared after software update. Maf readings are only a third of desired in live data which I don't know if it's because of egr blank or maybe another reason. She's also slightly down on power but no smoke.


I can post live data if helpful

Thanks in advance

[loot]

P251a can be removed if you gotop rpm limiting and set it to none.

I was going to suggest loose injectors but you've done them, how long ago was it done? It's possible they've worked loose.

I would also remove the blank just to see if it solves the problem, with the egr blanked there's no contra airflow so the maf should be reading higher than expected and the turbo working harder so you should get turbo over boost situation(eventually but not always ). Presumably the egr is still functional and not deleted?

[Hewzey]

Hi loot and thanks for the quick response. I've been to see Martyn and had software updated and egr deleted before I did all the work to it so dont think unblanking it is an option, the injectors have been out to put the upgraded clamps on and we cleaned the seatings and nozzle washers and redid assuming that the new clamps look beefier and would press down harder rather than bend like the old ones. Felt a lot tighter on the spanner after 6nm +180deg.

Do you think I should renew the copper washers and clamp bolts and redo just to rule it out? didn't see any oil on cam cover seals but they have been replaced too recently so maybe a better seal now is making me believe that injectors are sealed. No oil level change though.

What are your thoughts on aftermarket nozzle seals?

Will that dtc affect running in any way? Rpm controller sounds important.

Thanks again...

[loot]

Rpm controller is a resistance ladder connected to the van which allows you to pre set the idle speed for various reasons, most of us don't have them so the pcm update brings up the fault code as it'll set yours to 3 speed which you don't have the hardware for lol, setting it to zero gets rid of the code/problem. There was an earlier update that brought up the brake fluid level switch fault which never came up if you took the handbrake off before running the code test (would imagine it only showed on vehicles with the handbrake warning light) nice to know Ford thoroughly test their updates before sending them out

If the clamps etc are new and good then I'm not sure how it can be them? The rocker shouldn't have pressure in it so if there were pressure there due to faulty copper seals i think even new rocker/injector seals would allow oil past.

If the egr was deleted then unblanking it won't make a difference, i was getting a slight chatter when i hoofed my van and for a while i wondered what was causing it, i changed the clutch as a matter of course, and the crank sensor was a little bit dirty with metal, i really cleaned it and i refitted it making sure that the gap was correct, i now don't have any chattering and also in 5th i used to get a miss fire if i very slowly held the revs in a certain position ie. 49mph at 2k sort of thing, the miss wasn't there on acceleration just if i slowly held, it's gone now too.

I'm not sure if that is the cure for your problem tho.
Have you spoken to Martyn about your van?

[Hewzey]

Ok great cheers so no mad rush to reset rpm controller as I don't have ids I only have Forscan which can't do that service procedure.

I will look into the crank sensor thanks for the heads up.

Also from idle I get a small chatter when revs lift but goes after about 1200 rpm. Did your dirty crank shaft sensor show any other running probs?

I recently cleaned the inlet manifold and throttle body and the sensor in it was full up with crud. I believe it's the boost/map sensor. Don't know if I may of damaged when cleaning with carb cleaner and a toothbrush? Would this maybe cause fueling issues if faulty? No codes tho...

Also noticed a large air bubble in fuel line to pump, is this normal do you know? Just trying to rule out stuff it just sits in the higher part of the fuel line 'loop'?

So many questions lol ...
Cheers

[loot]

No other problems with running, no chatter other than when going for it.
Is there any way you can post a video? Most problems are solved by what you've already done lol

[Hewzey]

Lol, yeah I can post of knock in mornings on first start. Does it five times like a misfuelling rattle noise and spike in fuel pressure. Rpm doesn't move tho

Pulls good through the gears but coasting on motorway under light load gets noisy. Heavy load and it quietens down a bit.

Martyn suggested prob worn injectors so replaced and prv/scv done.
Defo sweeter to drive but just that noise grrr

I'll try videoing it

Cheers