Transit Mk.7 2.2 Puma water-contaminated HP fuel system

[valhalla]

Could I throw this out to the lions on the forum? (KarlB?) 2.2TDCi PUMA with engine type QWFA on a '56plate Transit.

The Transit came in on a tow-rope (I had to find that out myself - I wasn't there at drop-off!), apparently becoming increasingly more difficult to start when hot, then finally when cold as well. The fuel filter was in an appalling state (I have the pictures) with almost 90% content of water and biological growth, just a tiny bit of diesel fuel floating on the top. The fuel supply into the filter was good, with a clean flow of diesel under light vacuum. I primed a new fuel filter by vacuum through the HP supply port, and then watched the engine parameters whilst cranking. Basically the rail-pressure is out of control, with bizzare readings coming from the (AutoCom) scantool for rail pressure during cranking; it's either very low and scaled incorrectly, or very high and relying on the mechanical pressure relief valve to waste the pressure. I believed at the first measure that the rail pressure was high, due to unburned fuel wisping from the exhaust (low pressure would not permit injection on cranking - I think - unless Ford have cocked-up).

Anyway, the van wouldn't start, and it needed a sniff of ether to get any result. The rail pressure came back under some sort of control once the engine fired and had been blipped to 1500rpm, although the pressure was still not coming down to target. The following DTCs are recurrent during this sort of running;

DTC Description
P251A - Power Take Off, enable switch
- Open circuit
- No symptom
- Current
P1250 - Fuel pressure solenoid valve
- Stuck
- Intermittent
P02A4 - Cylinder 3 balance - injector restricted
- No symptom
- Intermittent
P116E - Fuel Tank Pressure Relief Valve Malfunction
- No symptom
- Intermittent
P0089 - Fuel pressure control valve
- Circuit Low
- Intermittent
- Leak detected
P0088 - Fuel Pressure Regulator Control Circuit
- Component failures

The question is; "Is it worth even bothering with?", or is this just another Ford knacker with an endless consumption of Denso injection bits and pieces? The imbalance on #3 (close to the rail entry for HP fuel from the pump) sort of suggests that this is going to need not only a new suction control valve, but new injectors as well. The only mitigation is that I cannot find any debris in the old filter (yet), but is that just round the corner?

The van will sometimes start cold, generally starts hot, but each time has a "bark" from the combustion system during starting, just before the usual codes are re-set and the rail pressure comes back into some sort of control.

[Monkey]

Where do we start?

The over pressure regulator in the end of the fuel rail is likely to have ejected itself, so I would check that out.

I bet the PCM software is miles out of date, there's been about 6 updates for 2.2 transit since new. All address EGR issues, unstable fuel pressure, hard starting etc

If the regulator has blown, replace it and the fuel filter, try and get a decent quality fuel supply (may have to drain tank?) and carry out a high pressure pump learn. If that's successful then great, if it fails and fuel pressure is too high then a metering valve is next!

I've seen 500-900bar of fuel pressure at idle. After a software update and high pressure pump learn, usually sorts them out.

[Karl]

Monkeys the man for ransit's


Sorry I don't touch them


But I'd second monkeys advice


Drop fuel tank and clean out properly , flush lines , new filter and fresh juice

Then go from there

[valhalla]

Thanks both for your replies. I'll put a list together for the customer and see where he wants to go with this. Some of the prices for the Denso bits seem to be a bit mercenary. Although I don't suspect the rail pressure sensor at this moment in time (it reads plausibly, and decays back to 0MPa steadily), that is something that doesn't tally with the part numbers being offered for this van - it seems to tally with a Denso item for a PSA van with the 2.2HDi - which puts a further unknown into the equation (part # I read late this afternoon was 55PP05-01). I'm happy enough to fix this van for the customer, but don't want to raise his expectations too high if it is just going to be one thing after another. Added to which, it's a '56 plate, and like every other Ford commercial in these parts, is grotty in the lower bodywork at a relatively young age.

[natedog]

Has he been buying fuel from the local scrappy?

[Stilo]

Mar 29, 2015 10:54:34 GMT 1 natedog said:

Has he been buying fuel from the local scrappy?

Or running it on home brew??

[valhalla]

Mar 29, 2015 10:54:34 GMT 1 natedog said:

Has he been buying fuel from the local scrappy?

As good as ......

I'd swear that the water had tadpoles swimming in it, there was certainly enough to make a pond. I've never seen a filter that's 90% water.

[remmington]

1. Top tank breather on these point the direction the van travels!

2. Filling breather splits on them as well

3. Rail over pressure valve bursts

4. Pump inlet metering valves jam and then burst the over pressure valves in the rail

Good news is Ford sell at kit, overpressure valve and pump inlet metering valve, you fit them then do a pump learn on Delphi or IDS.


I have seen all of the above, loads of times, on Mk7 Transit vans.


I have had to have the tank of several vans and extend the top breather with a slide on "snorkel" made out of 8mm fuel hose cable tied to the chassis.


Oh.... The metering valve is fitted with a huge spanner with very little access to undo the valve and they are FT.

[valhalla]

Well, the good and bad news with this one is that the customer doesn't want to take it any further. I explained that an overpressure valve and pressure control valve were on the cards, plus a drop of the fuel tank and a thorough drain of the bottom. I then explained that this was probably just the start of his problems, as I suspect that the injectors will be contaminated (I measured a misfire code on #3 twice in short succession). All in all, he is going to punt this one as S&R, he's already had a couple of inquiries. I don't blame him, there's another '56 Transit within a few miles of him doing just the same thing. The writing's on the wall for these.

I would have liked to have fixed it, to prove the point, but given there are better vans out there (this one's got rust appearing at the rear O/S sill and into the wheelarch) then the risk is not worth it when it's someone elses money, and I don't have time to take it on as a project and potential resale over and above the other work I have on the slab at the moment - shame really.