MK6 85ps suspected injector failure?

[James-B93]

Good morning all, my MK6 85ps is suffering from some symptoms that I think I have narrowed down to some/a faulty injectors but I’d just like a sanity check before I start going too mad! So to begin with it sounds very happy at high revs and when it makes this tally noise it is like a switch turning on. I’ll go up through the Rev range and it’ll suddenly change to this noise. I also have an exhaust leak somewhere in the engine bay that I am yet to find and this may be contributing.

My next issue is when I switch the engine off, I get quite a strong shudder right as the engine comes to a stop. So much so that I have heard it rock the van enough to make the handbrake squeak at the rear wheels. Is this likely to be because there is an imbalance of fuel going between the injectors or is it likely to be an engine mount issue? I do believe one of my mounts is slightly duff because when I throttle off there is a thump and on occasion there is a thump when engaging the clutch. However when I grab the engine and try rocking it there is no movement at all.

Does anyone think they could help shed some light on this for me as I don’t want to fit a new mount to have it wrecked by the strong shudder on shutdown etc. Any help will be massively appreciated!

[knobby1]

Best to get the codes read before doing anything drastic....guessing can become quite expensive. Fuel pump wiring can be fragile where it goes near the starter on the FWD's.

Your exhaust leak may be a cracked/broken EGR pipe...worth checking at least.

Lord Knobrot

[James-B93]

Best to get the codes read before doing anything drastic....guessing can become quite expensive. Fuel pump wiring can be fragile where it goes near the starter on the FWD's.

Your exhaust leak may be a cracked/broken EGR pipe...worth checking at least.

Lord Knobrot

Thanks for your reply! I’ve spoken to my mate that works as a mechanic and hopefully will be able to get it scanned this weekend. I will also check the wiring this evening to see if there is anything obvious.

In terms of the EGR pipe - is this a common issue? If so where abouts in the pipework should I be looking for a crack? Is it at the rear of the engine?

Thanks again for your reply

[knobby1]

In terms of the EGR pipe - is this a common issue? If so where abouts in the pipework should I be looking for a crack? Is it at the rear of the engine? Thanks again for your reply

Resonably common, see here:

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

Lord Knobrot

[James-B93]

In terms of the EGR pipe - is this a common issue? If so where abouts in the pipework should I be looking for a crack? Is it at the rear of the engine? Thanks again for your reply

Resonably common, see here:

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

Lord Knobrot

That’s perfect thanks a lot. I’ll check that pipe before looking elsewhere. Also think I have an oil leak from my injector seals so they may need to come out anyway. Hopefully if there is one (or more) playing up I might be able to see some signs of this. Thanks again.

I’ll update once I’ve had it scanned and if any codes come up.

[James-B93]

In terms of the EGR pipe - is this a common issue? If so where abouts in the pipework should I be looking for a crack? Is it at the rear of the engine? Thanks again for your reply

Resonably common, see here:

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

Lord Knobrot

I had a look at my engine last night and the EGR is in a completely different position to the imagine? When you look at the engine the EGR is at the front left corner of the engine underneath the inlet manifold? The EGR pipework then runs all the way under the inlet manifold round the right hand side (gearbox side) of the engine and is wrapped in steel woven insulation?

Does this sound right for the 2.0 85 PS engine? I also noticed the big DI badge on the engine and the current fuel filter has a big tick next to a TDCI badge and a big cross next to the DI badge...looks like I have the incorrect fuel filter fitted too...

[James-B93]

And as another update, scanned the van for fault codes this evening and nothing came up at all! At a bit of a loss

[martynx]

The TDCI filters are more restrictive, you dont normally get extreme symptoms from fitting one though. Unless its done more than say 20k & is blocked a bit.

[James-B93]

The TDCI filters are more restrictive, you dont normally get extreme symptoms from fitting one though. Unless its done more than say 20k & is blocked a bit.

Thanks for your reply, I will get the new DI one fitted and see if it makes any difference at all. Currently having a mare with the gearbox linkage and it’s not playing ball in the slightest!

[Altransit]

EGR pipe sounds to be the same as was fitted to my 85ps Mk6.

Mine cracked, and eventually broke, about 6" from the turbo connection at the back of the engine. There are two small bolts holding it on which can break off when removing if you're not careful. I simply loosened the pipe at both ends, slipped blanks under the flanges, and re-tightened.

The pipe is quite expensive to replace

[James-B93]

EGR pipe sounds to be the same as was fitted to my 85ps Mk6.

Mine cracked, and eventually broke, about 6" from the turbo connection at the back of the engine. There are two small bolts holding it on which can break off when removing if you're not careful. I simply loosened the pipe at both ends, slipped blanks under the flanges, and re-tightened.

The pipe is quite expensive to replace

Now that it’s been mentioned I think that it’s almost certain that mine has gone, I will be buying the blanks ASAP because it is filling the interior with exhaust gas if I put the fans on external rather than recirc! Thanks again for the info

[Jim Archer]

Leaking injector seals will do that as well.

Jim

[James-B93]

Leaking injector seals will do that as well.

Jim

What symptom are they likely to cause? I have an oil leak that I haven’t been able to locate and have found a thread on here from years ago with a similar leak path that turned out to be injector seals?