Noisy Fuel Injectors MK2 Transit Connect 15 TDCI EcoBlue

[Dazzonamission]

Hello Everyone,
I thought I would reach out to the community, I have a strange rattle on my Transit Connect 1.5 tdci ecoblue 2018 on 68 plate, it’s done 149k, but a engine replacement by Allen Fords under warranty in 2022, only 15k on new engine, all documented with receipts.
Purchased van in May 23, and was driving lovely, I had a rattle appear in Feb 24, and it was intermittent at first, but become very noisy between approx 1200-1800 rpm, I took van to a local specialist in Essex, and they replaced an injector, noise disappeared van run lovely for approx 70-100 miles, noise returned,
I once again returned to specialist, and they said another two injectors where showing high resistance, and needed replacement, van run lovely again for 70-100 miles noise returns.
This is getting extremely frustrating and expensive as I had 3 brand new injectors installed and coded in, and with labour across two visits £1200,
I opted to start replacing parts for my own piece of mind, and have replaced so far :-
Fuel Filter
MAF Sensor
Cambelt Kit & Waterpump
3 New Bosch Injectors
Now my local mechanic who changed the cambelt said the engine is mint, and timing was spot on, no issues with pulleys but changed the belt which looked pretty much brand new, but I did it for my own piece of mind.
He commented that when they was running the van outside the workshop, the smell of fumes was apparent, and the cab also smelt of fumes, and was running noisy.
They connected the van to the Ford Diagnostic System, and recalibrated the injectors, and the van quietened down, and was a pleasure to drive for 70-100 miles,
Unfortunately rattle noise has returned, engine very rough on idle, and almost stalls, but you take it for a drive it runs better with intermittent rattle, coming and going during my journey.
Local garage has raised a case with Ford Technical, and provided the data dump for them to analyse, but wondered if anyone has experienced a similar issue.
Hopefully someone can help me, it’s causing me sleepless nights and I can’t keep pumping money into it.


Regards
Darren

[metalworker0]

Had a look at your first post, when you first joined, you mention rocker arm bolts missing --- what about these?

Now then ,..i think this engine has hydraulic lifters...if it hasn't I'm wrong and disregard this post.

(note - very rarely does this engine cause trouble --- because of that we know little about it, as no one comes here to complain that much)

You are saying the noise is on and off, makes me think of the lifters

Maybe it was rebuilt / reconditioned / remade / overhauled or whatever term they like to use ..but they used some of the old parts,...so that's why injectors failing etc

i would not be surprised if the hydraulic lifters are as old as the rebuilt / reconditioned / remade / overhauled engine. as they left bolts out, so that alone casts doubts on their abilities.

in which case old lifters can go faulty --- stick or leak down, causing excessive rocker arm clearance. noise and cause power to go down.

There is no way of testing them really - without taking them out ..some mechanics know the exact noise one of these makes...a ford dealership would be dealing with younger cars and engines ..so even they would perhaps never get to hear a worn lifter.

Usually a hydraulic lifter can be put in a vice and squeezed...a good one would show a lot of resistance ..before the oil leaked out..a poor one would not feel the same - a well practiced mechanic would know the difference.

other facts about this engine are

its a Peugeot/ Citroen/ ford developed engine found in many of these cars..so there are many other forums to find out misgivings of this motor.

all the best.mark

[Dazzonamission]

Hi Mark,
Thanks for your reply, I completely forgot about the lifters, and yes Fords would effectively overhaul the engine, and replace a lot of the components/parts, from original engine.
I’ll ask the local garage to check the lifters, it’s strange how the injectors are recalibrated and it runs like a dream for 70-100 miles,
But really appreciate you reaching out, we should also hear from
Ford Technical shortly, to see if they can see any issues, they have comeback
requesting further data captured during the diagnostic test,

Thanks again

Darren

[benlikesound]

Hi Mark,
Thanks for your reply, I completely forgot about the lifters, and yes Fords would effectively overhaul the engine, and replace a lot of the components/parts, from original engine.
I’ll ask the local garage to check the lifters, it’s strange how the injectors are recalibrated and it runs like a dream for 70-100 miles,
But really appreciate you reaching out, we should also hear from
Ford Technical shortly, to see if they can see any issues, they have comeback
requesting further data captured during the diagnostic test,

Thanks again

Darren

Hey Darren,
I've had an nightmare with my 2018 1.5 Ecoblue Connect. Sounds like exactly the same issue you had, but worse...
Along with the knock, mine is also down on power and has horrendous misfires. Pretty much undrivable. It also has a weird issue where the "Low Fuel - xx Miles Till Empty" warning flashes on the instrument cluster for a fraction of a second every mile or so while driving, but only when the tank is more than 1/8th full. This low fuel warning issue is noted in a Ford Technical Bulletin (SSM 48266) and is supposed to be resolved by IPC update to latest version using Ford Scan Tool.

I've had all the injectors replaced, the turbo, all the filters, camshaft has been removed and found to be without fault, and the previous owner had the DPF and Adblue Module replaced, and a load of other stuff too.
I've suspected a dodgy engine remapping was done to hide issues before sale. Allen Ford Coventry claim they've re-installed the ECU software, but the fuel light issue is still happening, so don't think they have.

If you work out what's wrong with yours, I'd love to know what it turns out to be. Would really appreciate an update when you have one.

[Dazzonamission]

Hey Ben,
Wow, I feel your pain, you sound like you are going through the same scenario as me, I pretty much gave up finding a solution and just accepted that I must have a lemon, but can’t understand how the van was great for 5 months, I haven’t heard back from the garage who was waiting on a response from Ford Technical,
But my van threw up some warning lights briefly about DPF and I needed to run engine to clean DPF, but seconds later, I had a warning Exhaust Filter Over Limit Service Now, with the spanner icon, I took the van for a 40 minute drive, and the lights remained on the dashboard, how frustrating…. I decided to clean my DPF, it had a forced regen done back in Oct 23, but on this occasion I did not use a DPF cleaner, as I had spent about £80 on them before without any improvement hence taking it to the garage in Oct 23, instead I mixed up 1 dishwasher tablet, seen this on YouTube, to 700ml of warm water, and using a bottle pump hand gun with hose run the pipe into the DPF after unscrewing the sensor, I run it all through and left it for 20 minutes, I then drove the van 2 miles, on turning van off and on again, spanner light had gone, I plugged in my Autel scanner and cleared the two DPF faults, van was running smoother now, and rattle was intermittent and not so loud.

so I decided to get a performance remap and carbon engine clean done, it was on offer from Remap Kings £290 after the remap the engine was still rattling but had improved idle, which was originally chugging and struggling on idle,
I did a forced DPF clean again only using dishwasher tablet, and the white smoke coming from the exhaust, and the smell of fuel, DPF regen completed and van is at this time of writing back playing nice, with no rattle,
I believe the ECU is very much still learning the engine, and will improve further.
I hope this is helpful in some way shape or form, I certainly think the issue was the DPF and while the cleansing helped, the forced regen was what was required to fully clean the DPF.
But I also think the remap has also helped massively,
I would get your DPF checked out, as all the symptoms which I was sure was injectors, where related to soot build up.

Best of luck

Darren

[Dazzonamission]

Just to add further, Allen Ford Coventry replaced my engine under warranty, from the previous owner, I had no service history apart from receipts for engine replacement all itemised on warranty invoice.

I never realised the DPF where such a issue on these vans, and I just don’t do the miles to keep it tip top, I am
Considering buying a launch DPF gun, and a compressor to clean it monthly.

Symptoms I experienced with DPF, was rough idle, misfire, got slightly better when warmed up, rattle, easily mistaken for injectors, hesitation, I would be cruising and van would slightly stutter.

And more frustrating no errors, showing on scan tool, then one day you simply get the amber warning icons, Exhaust Filter over limit service now.
Then it shows on scan tool, I will be carrying out another DPF regen soon, hopefully to keep the van running tip top.

Best of luck

[Dazzonamission]

**UPDATE**
PCM was the issue, as called out by my Indy Ford Specialist, CH Motors, Basildon, Essex
Van had PCM replaced by Allen Fords now running sweet, even Fords were sceptical this was the issue, and the £1300 gamble has paid off.
Hope this helps someone with similar issues, Fords advised it’s pretty unheard of, but said they had a transit custom in a few weeks back with PCM requiring replacement.


Regards
Darren