Ford TDCi won't start after conversion.

Hello everyone!

After installing a used engine, my workshop had to remove the ESP (Electronic Stability Program) again due to a sealing problem. Before the removal, the engine ran perfectly at idle. After the sealing issue was resolved and the ESP was reinstalled, the engine initially only ran on three cylinders at idle, or it would misfire. When given more throttle, it supposedly ran smoothly. Now, it doesn't want to run at all...
It seems like fuel is being delivered, and pressure is supposedly being built up (but how much? I have no idea).
The workshop is now at a loss and doesn't know what else to check... They've already examined the timing, etc.
They were planning to try pulling it today, but I don't know the result of that attempt.

Today, I called another workshop (which is unfortunately quite far from my car), and the master mechanic suggested that the problem might be due to insufficient current reaching the quantity control valve. He said it needs around 20 amps, and that should be checked with a clamp meter. The cause could be the immobilizer or a defect in the wiring.

The mechanic in the workshop where the car is located said that there are 12 volts coming in, and that the immobilizer is active when this is indicated.

What's the deal with the 20A?

Does anyone else have any helpful information?

Thank you very much!
greetings
guni



Car: Ford Focus 1, 74 kW TDCI engine, Delphi fuel pump, pump has approximately 55,000 km, injectors have approximately 40,000 km.

There's nothing stored in the error memory.
greetings
guni

Hi Gunni,

Quote:

Before the breakdown, the engine was running perfectly fine at idle.

Workshop or hobby destroyer???

Could he have possibly damaged the pump or failed to reset the settings?
I don't see any other options here.
The only solution is to have the workshop fix it properly, or to switch workshops.


However, a remote diagnosis is not possible in this case, as the location of the fault is obvious.

Good luck to them... and hopefully the pump doesn't break down.



Wool.

Hello Wolle.
It's a free workshop and also a Ford authorized service center, and I'm now at a loss.


The suggestion to measure the current at the flow divider came from a Bosch workshop, which also works on Delphi systems. The injectors were replaced there last year (after a dealership tried to sell me a new pump, or rather, said a "new" one would be the best option... that's why I drove my car from North Hesse to North Bavaria). I actually have a lot of confidence in that shop in North Bavaria.

So, who can provide some information about controlling the flow divider?
Greetings and thank you!
guni

Hello again.
Apparently, the control of the fuel injectors has also been checked, and they seem to be working correctly.
It seems to me that the fuel injection pump probably needs to be bled to remove any air, and that the process may have caused it to become strained, which is now causing the valves to seal tightly. This assumption is supported by the fact that the starter motor has been damaged. While it wasn't the most expensive starter, it was working perfectly before and was only about six months old.
I want to be able to definitively rule out any possible alternative causes.
greetings and thank you!
guni

Hello again...

"The workshop has informed us that the pump must have had a pre-existing defect... It's impossible for the fuel injectors to close so quickly just by bleeding the system."

Well, after bleeding the pump, one of the nozzles apparently wasn't working properly when idling.
Shortly after that, the engine apparently stopped working altogether.
Is a single purging cycle sufficient to clear the nozzles?
"Thank you!"
guni


PS: There are shavings in the diesel filter...

There was once a problem with Bosch CR pumps. They had a faulty coating, which caused them to fail. Consequently, the damage was approximately 4500 euros (complete fuel system replacement).

With a CR pump, you should avoid bleeding the air out of it, unless the manufacturer (Bosch) specifically instructs you to do so. Otherwise, it will likely become stuck.