How to test if TDDI injectors are knackered/worn

[Louey]

Still not got the van back Mechanic has Covid.

He did say that he reckecked the timing and the cam bolts/rocker bolts (?) where tight. He is now suspecting that the pump and the other one in a Connect he is doing could be a faulty batch! Who knows, watch this space whilst I get the bus to work and back

I won't be going back after I do get the van back, that's for sure.

[Louey]

Got the van back.

Mechanic said he has tried three new pumps on the van and it hasn't fixed the issue - fault codes pointed at pump and Fuel timing Solenoid (new solenoids come with each pump. He apparently said he swapped out at least one injector, though he couldn't tell me which one/s - still the same issue. Idles okay, though it seems to be smoking now

Drove it to work this morning - struggled starting, smoked and and needed a bit of revs to stop it stalling, idles okay after that. Go to accelerate and there is hardly any power, struggled between 15 and 30mph. Engine rattles or it's diesel knock - once foot is off the accelerator it sounds okay.

My plan, before finding a decent garage:
Try and check that there are no leaks in the diesel pipes
Replace fuel filter
remove rocker cover and check cam bolts (ladder bolts?) or see if any noticeable looseness or sticking.
I've ordered an injector (hopefully from a working engine) and I'm going to swap out one injector at a time to see if it changes anything - though quite a few people, except the mechanic) has said it most likely isn't an injector.
See if Forscan can read injectors when engine is running - will have to persuade wife to either drive or look at laptop on a test drive.

Does that sound a reasonable plan? Or shall I just burn the MOFO?

Still asking/looking for a decent garage in South Birmingham.

[Louey]

This is me preparing myself watching youtube videos so i don't come unstuck and pay ££££££out in the future . the video is slow but there is a lot to learn from it

Take the things out ..and look on it as servicing!

https://www.youtube.com/watch?v=guYFnOMlR_k

buy a used set and have them serviced as in the video, keep them safe ready to swap out when there is trouble

can anyone see anything wrong with my logic ?

all the best.mark

Nice easy to understand video - I don't think I can go wrong if I take out the injectors to check them. Thanks.

Do MK6 injectors have seals/washers at the bottom? I know they have seals/covers on top - plan on getting a new set of them.

[metalworker0]

Yes, i hear there are copper washers under them , and it's my understanding that you should only buy genuine ford ones ..as copies are not up to much (too thin /poorly made).

Depending on the looks of them, or if you cant get to a ford dealer and if not grooved and faces look good, you can anneal them, means taking them out heating them up with a blow torch --- or putting them over a gas cooker burner ..and quenching them in water. This will make them soft and crush-able ..so will seal again easily.

all the best.mark

[scas]

The steel washers are usually welded to the injector cos of time and heat, the seals are just metal/rubber things and reuse them all.

[Louey]

The steel washers are usually welded to the injector cos of time and heat, the seals are just metal/rubber things and reuse them all.

So do I get copper or steel washers?

[knobby1]

The steel washers are usually welded to the injector cos of time and heat, the seals are just metal/rubber things and reuse them all.

So do I get copper or steel washers?

Mk6 TDDi has steel washers...copper washers are fitted to the Mk7.

Lord Knobrot

[Louey]

Took two injectors out, dismantled them and cleaned them up. Both had good spray pattern from their nozzles.

I removed the sleeve off injector #1 and I broke the little circlip that helps it stay in place, so I couldn't refit injector #1. Can you get the circlip as a spare part anywhere? I've had a look and can only find replacement nozzles so far. Not too desperate as I should be getting an injector in the post tomorrow.

[knobby1]

Took two injectors out, dismantled them and cleaned them up. Both had good spray pattern from their nozzles.

I removed the sleeve off injector #1 and I broke the little circlip that helps it stay in place, so I couldn't refit injector #1. Can you get the circlip as a spare part anywhere? I've had a look and can only find replacement nozzles so far. Not too desperate as I should be getting an injector in the post tomorrow.

I don't think Ford list them separately but your local diesel specialist should be able to help.

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

Lord Knobrot

[Louey]

Replaced the injectors this morning, yep still running crap. I've found a place in Small Heath that will test the injectors for £10:each, then I can see if they are the problem.
The engine seems to hunt a little when idling, not sure how well you can pick it up in the video.
https://youtube.com/shorts/nxdvyk7-qkM?feature=share

[Louey]

The injector test showed one has low pressure and one is returning a bit more fuel than it should. Replaced the one with low pressure with a spare the garage had. Runs a little better but still not great. I might cost up the parts for rebuilding all four injectors.

So, still noisy and sounds like diesel knock.
Acceleration is a little better but not great
Starts straight away.
Noticed garage had lost the EGR blanking plate, new one came but they sent me a Mk7 one
Need to read codes again.

[Louey]

Still at it with my van.

I took the rocker cover off last week to see if there was anything obvious. Took the rocker bars off today to check the rocker arms - nothing obvious, though the left hand set of rocker arms didn't have springs between the pairs, the right hand did. It starts, but smokes a lot (see video) and still sounds terrible and still low on power.
https://photos.app.goo.gl/7gGKwgbcYCuNrqUr9
https://photos.app.goo.gl/2GGbR9k5UiAVQHJm8
https://youtu.be/SQOS_KV8ykc
https://youtu.be/eFEGxdcP46Q
https://youtu.be/nxdvyk7-qkM
A garage I've been recommended has a couple of weeks waiting list. I was trying to sort a diagnosis beforehand.

Just spotted one of my ratchet spanners in the washing machine too

[knobby1]

I was trying to sort a diagnosis beforehand.

Have you not had the codes read..??

Lord Knobrot

[Louey]

Read them last week. P1564 and p1049 - even after a new pump and solenoid.

[Louey]

Yeah, P1564 and P1049 despite a new pump and solenoid.