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1.6 Tdci Knocking On Revs


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#1 Carl0s

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Posted 10 January 2013 - 09:45 PM

First of all, sorry for opening another thread nearly on the same issue as the one before. But the forum doesn't allow to edit the thread title.


So, -06 1.6 TDCi knocks, but only when you got over 2700rpm on the engine. it knocked - i changes the oils and it got a lot better, then i washed my engine bay today, and the knocking got back to square one. (oils are driven 400km )

The sound comes in both, acceleration and deceleration (actualy i think it gets worse when your doing engine braking) so i dont think its "diesel knock". And from the inside, it sounds like it coming from the lright side of the engine.

So any ideas? tappers? Cam chain tensioner?

how black should the oil be in these? Since mine is allready pich black, when i compare it to my previous tdci mondeo, it had lot clearer oils eaven after 10 000km. but, in the mondeo the EGR was disabled...

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#2 stef123

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Posted 11 January 2013 - 12:35 AM

Diesel engine lol does tend to go black quite quickly so I wouldn't worry about that to be fair.

The knocking sound could be a main or big end bearing.



#3 Carl0s

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Posted 11 January 2013 - 06:58 AM

Diesel engine lol does tend to go black quite quickly so I wouldn't worry about that to be fair.

The knocking sound could be a main or big end bearing.


I would think that if it is main bearinf, or big end bearing, it should make atleast some knocking pre 2700rpm?

Does these things have the same kind crankshaft accessory pulley as in 2.0 TDCi mondeo? My mondeo had the crank pulley fail (the outter ring spun complitely freely compared to the center part ) The sound is bit similar what the mondeo made on idle whit bad pulley, but unlike mondeo, this is quiet on idle, and noisy on revs...

So, last night i couldn't cach sleep (too many red bulls during the day) and i started to wonder if it could be something that the accessiry belt has been oily, and caused it to slip, making the crank pulley less noisy. Now i washed everything whit industrial grade solvent, the belt got some more grip and started to make noises...

But, still open for ideas :)

#4 stef123

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Posted 11 January 2013 - 09:22 AM

Being a diesel though which male alot of engine noise it could be hard to detect the noise.

Those damper pulleys can become noisey, but if its bad enough to knock then I think you would see it when running.

#5 Carl0s

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Posted 11 January 2013 - 11:09 AM

Hobla!

http://www.tdocuk.co...php?f=41&t=5329

Exacly the same! Any ideas ?

#6 Carl0s

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Posted 11 January 2013 - 07:01 PM

Update:

Just tested on idle:

From idle, slowly raise the rpms and it starts to knock at ~3000rpms, release the throtle and it knocks.

From idle, stomp it to bit over 2000rmp, and release throtle... and you get the knock... so it knocks on rapid decelarion and over 3000rpms...

Injectors ?


#7 Carl0s

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Posted 12 January 2013 - 12:27 PM

Progress update:

Acording to the bits of information ive found from the web, the number 1 suspect for the issue is worn injectors. I'l try to do a leakoff test this weekend to confirm it.


If it comes down to that, i've found some reasonably priced injector sets from ebay, and i think i just go for those. Any tips for the injector change? I guess i need to get seal kit from the dealer, but does these require any injector coding?

Ive read around the web, and some places say that they need to be recoded like delphi, some says that you only need to reset the PCM, and some say just plug'em in, the PCM will learn the new injectors quite quick.

#8 stef123

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Posted 12 January 2013 - 12:33 PM

As far as I know all tdci injectors need to be coded

#9 Carl0s

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Posted 12 January 2013 - 01:09 PM

As far as I know all tdci injectors need to be coded


thats the cach, example this: http://www.autodiagn...ing_tdci_ad.pdf clearly states that the injectors need to be coded. but then again, by googling "1.6 tdci injector coding" and "1.6 hdi injector coding" you find the "flame wars" between "code'em!", "reset'em!" and "just smack'em in and ride like you stole it!"

You see why im getting confused? =)

#10 TDCiST

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Posted 12 January 2013 - 04:53 PM

ah, you've quoted TDOCUK!

Yeah your injectors will need coding to make sure the ECU knows how much to inject and how long to etc etc AS each injector is different... not masiively but when running on such fine tolerances as these do....

I'll see if i can find the article i read on injector tolerances, and why they need coding... It made for interesting reading!

#11 Carl0s

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Posted 12 January 2013 - 06:08 PM

Well well, after pocking hang-overed brother whit a stick (he's manager on automotive shop that i use as a garage) i got to the garage planing on doing the leak-off test.

I washed the enginebay on wednesday, and havent realy looked under the bonnet after that. Well, gotted the car in, popped the hood and took an eye on the injectors... No need for leak off test. Injectors 1 & 3 were wet from the root, and injectors 2 & 4 were dry ( pics: http://imgur.com/a/32CIS - the numbering starts from the cam belt side).

So, skipped the leak-off test and were planning to check the turbos oil-pipe mesh... but in order to get our hands on it, it seems like you need to take the turbo and exhaust manifold of. But, the on the upper end of the feeder pipe, all looked good. There was oil, and it looked pretty much same as on the dipstick. Also checked the mesh on the vacuum pump, and it was clean.

So, i guess next step is to get the seal kit from the dealer, and mondeospares sayd theyll be in contact if they can get theyr hands on for a propper set of 1.6tdci injectors.

That leaves me for coding? What would be the ideal way? buy my own ForDiag, FSuper, FO-COM or change the injectors, hope it starts and drive it to dealer?


EDIT: Forgot, as you can see, someone has allready done something to the injectors since they are all numbered... Would be nice to know what it might been. The car has full Ford service record, but there is no mention on the book that theyve mendled whit the injectors (but there is notes like "wheel bearings changed etc etc)

EDIT2:

Or what do you think? Should i just buy the seal kit, and clean the injectors, witch saves me from recoding them (i got industrial ultrasonic cleaner at work that i could use to clean em) or buy new used set?

#12 Carl0s

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Posted 16 January 2013 - 07:13 AM

Allright, update:

Friend loaned me a commonral leakoff test kit, so im planning to do a leakoff test today, in order to determine if i should just change the seals, or change the injectors while im at it.

Anyone has any info what the leakoff should be, in example 300sec intervall? I found leakoff test for mondeo (30sec idle, 30sec 2,5k rpm, 30sec idle, etc etc) that should give 25ml whit propper injectors... Anything like that for focus ?

#13 Carl0s

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Posted 16 January 2013 - 04:07 PM

Did the leakoff test.

Cylinders counted from the timing case, 120sec period

1: 37.5ml
2: 34ml
3: 65ml
4: 37.5ml


I guess there's my problem... :)

#14 stef123

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Posted 16 January 2013 - 05:19 PM

Safe to say you found your answer then...

Are you any further forward with injector coding?

#15 Carl0s

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Posted 16 January 2013 - 05:28 PM

Safe to say you found your answer then...

Are you any further forward with injector coding?


I contacted Tomas from ForDiag abaut the coding. Atm the software does not support bosch injector coding, but he has all the required information for doing it. He promised to check how much labour is needed, and then he calls back.

The last resort is, if it does not eaven start, to tow it acros the street from my garage to Ford for recoding... cant be more then 1h labour... cant...

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