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Help needed identifying a broken wire on mk7 engine

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Help needed identifying a broken wire on mk7 engine

Postby NoMoJo » Fri Oct 22, 2021 9:37 pm

2009 Transit van 2.2 tdci FWD euro 4
I was changing the fuel pressure sensor when i noticed a broken connection, it's kinda hard to explain where it is other than it's to the left of the fuel pressure sensor (left side of fuel rail)
20211022_195653.jpg


Spent a few hours serching but not sure what the part is actually called, it did have a part number on the housing but it must need cross referencing as my searchs found indicator stalks. lol
20211022_195917.jpg


Thought about drilling the center then reconnecting with a self tapper, but concerned it might be resistor or something?
20211022_200044.jpg

.
Hopefully someone can identify the part needed or confirm its ok to drill the center then reconnecting with a self tapper
(Newbie so apologies if it's posted in the wrong category)
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Re: Help needed identifying a broken wire on mk7 engine

Postby knobby1 » Sat Oct 23, 2021 9:02 pm

Glow plug harness, very common for them to corrode and break.

#6M091 here.:

http://www.catcar.info/ford/?lang=en&l= ... g4NzkrMTMz

Lord Knobrot
2008 2.4L RWD 170+PS 6-speed 350 LWB High Roof.

When I die, I want to go peacefully in my sleep like my Grandfather, not screaming like the passengers in his car..!
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Re: Help needed identifying a broken wire on mk7 engine

Postby NoMoJo » Sat Oct 23, 2021 10:34 pm

Cheers pal
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Re: Help needed identifying a broken wire on mk7 engine

Postby knobby1 » Sat Oct 23, 2021 10:39 pm

NoMoJo wrote:Cheers pal


Can I ask why the fuel rail pressure sensor was replaced..?? They rarely fail.

Lord Knobrot
2008 2.4L RWD 170+PS 6-speed 350 LWB High Roof.

When I die, I want to go peacefully in my sleep like my Grandfather, not screaming like the passengers in his car..!
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Re: Help needed identifying a broken wire on mk7 engine

Postby NoMoJo » Sun Oct 24, 2021 9:32 pm

Only just bought the van as none runner. All i was told is its hard to start, when it did start it wouldn't idle without increasing rpm & sounds ruff.

Managed to get it started after i changed the gearbox last wk, engine sounds good but fuel side aint happy and ran as mentioned above, so thought be best if i replace fuel sensor, relief valve and presure regulator? (not sure of correct names for them)
Then give rest of fuel & air systems a clean/ decoke.
When she starts/ runs smother i'll clear dtc's & run learns etc.
(Im a backyard mechanic so I'm probably doing things in wrong order)

Removed fuel rail to get to the glow plug wire you mentioned, bought a new 1 + 4 plugs.
Started removing the manifold, just my luck all the bolts are heavily corroded. Got 4 loose but looks like I'll be tacking bars onto the rest... Stopped hitting scockets on at 6mm :lol:
Also whipped the injectors out (2 seals were leaking) and removed turbo (oil leak from gasket) + actuator had snapped the connection pin.. made a new one, old one just taps out.

Anywhoo, I'll stop waffling
Cheers for the interest and info pal, its appreciated
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Re: Help needed identifying a broken wire on mk7 engine

Postby knobby1 » Sun Oct 24, 2021 9:56 pm

NoMoJo wrote:Only just bought the van as none runner. All i was told is its hard to start, when it did start it wouldn't idle without increasing rpm & sounds ruff.

Managed to get it started after i changed the gearbox last wk, engine sounds good but fuel side aint happy and ran as mentioned above, so thought be best if i replace fuel sensor, relief valve and presure regulator? (not sure of correct names for them)
Then give rest of fuel & air systems a clean/ decoke.
When she starts/ runs smother i'll clear dtc's & run learns etc.
(Im a backyard mechanic so I'm probably doing things in wrong order)

Removed fuel rail to get to the glow plug wire you mentioned, bought a new 1 + 4 plugs.
Started removing the manifold, just my luck all the bolts are heavily corroded. Got 4 loose but looks like I'll be tacking bars onto the rest... Stopped hitting scockets on at 6mm :lol:
Also whipped the injectors out (2 seals were leaking) and removed turbo (oil leak from gasket) + actuator had snapped the connection pin.. made a new one, old one just taps out.

Anywhoo, I'll stop waffling
Cheers for the interest and info pal, its appreciated


If you've replaced the SCV & PRV and pressure sensor, were they genuine Ford/Denso items..?? Non-genuine ones tend to give trouble and often fail the learns.

Lord Knobrot
2008 2.4L RWD 170+PS 6-speed 350 LWB High Roof.

When I die, I want to go peacefully in my sleep like my Grandfather, not screaming like the passengers in his car..!
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Re: Help needed identifying a broken wire on mk7 engine

Postby NoMoJo » Sun Oct 24, 2021 10:35 pm

Bought the cheapo's £60 for the set :(
Didnt realise i should have bough genuine/ denso until i read a post yesterday about cheapos failing, think you'd commented same. Lol
Ahh well, live n learn
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Re: Help needed identifying a broken wire on mk7 engine

Postby knobby1 » Sun Oct 24, 2021 11:31 pm

NoMoJo wrote:Bought the cheapo's £60 for the set :(
Didnt realise i should have bough genuine/ denso until i read a post yesterday about cheapos failing, think you'd commented same. Lol
Ahh well, live n learn


Try them first....you might get lucky. Crazier things have happened.

Lord Knobrot
2008 2.4L RWD 170+PS 6-speed 350 LWB High Roof.

When I die, I want to go peacefully in my sleep like my Grandfather, not screaming like the passengers in his car..!
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Re: Help needed identifying a broken wire on mk7 engine

Postby NoMoJo » Tue Oct 26, 2021 2:09 pm

knobby1 wrote:
NoMoJo wrote:Bought the cheapo's...Ahh well, live n learn


Try them first....you might get lucky. Crazier things have happened.

Lord Knobrot


Managed to remove the inlet manifold & found light carbon build up :shock: :lol:
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Re: Help needed identifying a broken wire on mk7 engine

Postby NoMoJo » Tue Oct 26, 2021 2:15 pm

IMG_20211026_123149.jpg

IMG_20211026_123518.jpg

IMG_20211026_123557.jpg

IMG_20211026_123624.jpg
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Re: Help needed identifying a broken wire on mk7 engine

Postby NoMoJo » Tue Oct 26, 2021 2:20 pm

Snapped pin on turbo actuator i replaced
IMG_20211026_135434.jpg
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