Custom 2.2 euro 5 clacking / knocking

[paul.h]

Hi
Hoping someone can Give me some advise to track down a clacking/pinking noise on my new to me van ( 2.2 2015 transit custom euro 5).
I think its injector / timing related but no Idea what I should call up on forscan PID Data to find out if somethings out, theres no fault codes.


Bit of back storey I got the van in a bit of a sorry state spewing out oil with lots of backpressure and accelerating on its own.
Did an injector leak test (24ml for 4 mins tickover on all injectors) and a compression test ( all cylinders 300 bar + ) to check the motor wasnt knakered before i went any further.
Traced the problems to badly leaking injector seals/blocked rocker cover breather and a split turbo hose. So replaced rocker cover , machined the seal faces and put new seals in + replaced turbo hose and cleaned oil out the pipes and intercooler ( that was fun...not)

The van was a bit ticky when it was all back together so flushed the oil and ran some fuel cleaner through, and it quietened it down to a reasonable amount over next 1500 miles. Even started tarting her up/towbar/reverse camera/new stereo etc.

But the clacking is back , and it feels like a minor hesitation /missfire when accelerating between 1500rpm to 3000rpm.

It only ticks when its getting fuel , so droping revs or going down a slight hill and its quiet.

heres a video of what it sounds like + injector buz test

https://youtu.be/51lze05yfkU?si=9a-zdeS6zmCd_yjm


Cheers for any help

Paul

[Radiofence]

I might be completely wrong, but I had a vivaro engine do exactly the same, then started to be difficult to start. Got the engine replaced and was told one of the conrods was broken at the piston end.
The noise wasnt there when going downhill, which is what reminded me of yours.

[metalworker0]

been all over youtube .. looking for worn camchain noise videos on 2.2 .. only found fixing ones .. no running and listening ones .. so cant help.

all the best.mark

[knobby1]

If the engine has previously "runaway".... you mentioned it accelerated by itself...it may have internal damage, possibly a small end conrod bearing/bushing failure...hence the noise on acceleration or under load and not on overrun, if it was a loose injector clamp or poorly rocker...it would make a noise all the time.

Lord Knobrot

[paul.h]

If the engine has previously "runaway".... you mentioned it accelerated by itself...it may have internal damage, possibly a small end conrod bearing/bushing failure...hence the noise on acceleration or under load and not on overrun, if it was a loose injector clamp or poorly rocker...it would make a noise all the time.

Lord Knobrot

Hopefully not ...but its crossed my mind , the "runaway" was at the garage for its yearly emmision test , bloke stalled it out fairly quick. I've been driving it for about 2000 miles since replacing the parts causing the issue , it hasn't blown up, not what you would expect from a knackered conrod......again i hope.

Need to do some forscan tests before condeming it , one odd thing is i tried to do an injector pilot learn and it just fails , but only been using software for a couple of days so could be doing something wrong.

Can you change pistons/ conrods with just sump and head off?

Cheers
Paul

[knobby1]

Can you change pistons/ conrods with just sump and head off?
Cheers Paul

No unfortunately, the Puma engine has a mid-sump, Ford call it a "stiffener", can't get at all the rod bolts/caps from underneath, timing cover, gearbox and rear main seal retainer have to come out....might as well pull the engine.

Lord Knobrot

[Frag]

That sounds normal to me for a stage 5,certainly doesn’t sound to have any mechanical problems.
You will improve any injector noise if you can get pilot correction to complete.
Update pcm to latest software if you can (has it ever had a remap ?)
Check correction factors are right per cylinder also

Does it still have the thick rubber cover over injectors/ top of engine because that makes a real difference to the noise you can hear in that clip.
Also make sure the boot at bottom of steering column where it goes through floor is good and fitted correctly,as again if that is not secure and fitted right,you get all that noise into the cab …..

[paul.h]

Cheers for that ,

i'm hopefull its something to do with software, especially as it has a hesitation between 1500-3000 rpm like a slight missfire.

Correction factors good , will try again to get pilot correction to work , wish forscan whould say why its failing.

No remap on van , straight from a company.

No idea how to do a PCM software update yet as new to forescan, would I need the "beta" software installed to do this , have a paid subscription and downloaded the beta version but dont want to go in blind and potentially brick it.

still have rubber cover .

That sounds normal to me for a stage 5,certainly doesn’t sound to have any mechanical problems.
You will improve any injector noise if you can get pilot correction to complete.
Update pcm to latest software if you can (has it ever had a remap ?)
Check correction factors are right per cylinder also

Does it still have the thick rubber cover over injectors/ top of engine because that makes a real difference to the noise you can hear in that clip.
Also make sure the boot at bottom of steering column where it goes through floor is good and fitted correctly,as again if that is not secure and fitted right,you get all that noise into the cab …..

[paul.h]

So , thought sod it and updated the PCM with forscans latest file ( said original not available).

Took van for a run and its definately faster and a bit smoother/ more free reving. But still has a bit of ticking though not as bad and doesnt always do it.

cleared pilot learned values and started Pilot correction learn , van reved it self up and down to 4000 rpm for 10 mins and then failed with message "possible cause high battery voltage"

Forescan showing battery voltage as 15v while running
did a Bcm!!! ( battery monitoring system) reset but alternator still charging at 15v.

Is it possible to turn off the smart charge system? just want a straight 14.2v , I think its getting 15v as the bcm thinks the battery is deeply discharged due to me charging it directly on battery posts.

2 steps forward 1 and 3/4 back i guess