Focus MK2 2.0 TDCI - Wont Start!!

[3ll]

Looking for a bit of guidance on starting issues im having with my 2.0 tdci mk focus estate. 

A few days ago it was difficult to start the car and i had to leave the key turned and the engine turning over for around ten seconds before the car spluttered into life - followed by a big white cloud of smoke out the rear.  after a minute or so the car settled down, the smoke cleared and the car was running fine. 

I then had the same issue a few days later, again, after a minute or so the car settled down and was running fine. 

I then had an issue the very same day where the car kangaroo'd a little whilst driving steady at 30MPH, this was followed by the engine dying completely and an engine management warning coming up on the dash. I coasted to the side of the road and turned the ignition off, I tried to start the car and it started absolutely fine no issues at all. 

At this point I realise that there is an issue and mentally tell myself to get the car checked out as soon as I can - The car continues to drive fine for the rest of the day however and I intended to go to a local garage the following day and get it checked out. 

Anyways, were now on the next day, I go out to the car and cannot get it started at all, the engine turns over however it will not fire. nothing. 

I had a look at the fuel line and noted that there were air bubbles in the clear line from the filter running to the fuel pump. 

I also noted that the fuel line was not securely clipped onto the fuel pump, I securley reconnected this and turned the engine over, Fuel was seen pulling through from the filter however a huge bubble of air was also in the line. 

I cracked open the bolts on the fuel lines going into the injectors one at a time and could see they were all pushing fuel past OK - I nipped these back up and thats as far as I have got. 

The problem I now have is I cannot get to a garage as the car wont drive, and I am not sure what to do or what may be the issue. 

 

Does anyone have any advise or had similar happen? 

I only got the car two months ago and i'll be honest its my first Ford, and also my first diesel so im a little outside my comfort zone on the mechanical side of things! 

 

 

 

[Focusoap]

Have you changed the fuel filter recently?

They can be very temperamental with inadequate, restricted flow and entrapped air in the fuel system feeding the HP injection pump. Maybe worthwhile replacing it if it hasn't already been done. They can be tricky to get going afterwards! There are plenty of tips on this forum how to bleed them properly.

[Tdci-Peter]

3 hours ago, 3ll said:

an engine management warning coming up on the dash.

It is always worth having a scanner handy. Any cheap OBD2 scanner (from well under £15) will show most engine codes. It would help pin the problem down a bit.

Air getting to the Diesel pump is disastrous for most Fords. There is no tank pump, and the main pump just will not suck air at all well. The best way to prime them is to use a decent priming bulb or pump on the input side of the filter (before the filter), and ram fuel hard into the main pump. There is no risk of getting dirt into the HP system and writing off £1000 worth of pump or injectors, and it is reliable. But it does need some kit.

Once air has got through the 1st stage of the main pump, it causes few problems, just maybe a stutter. The HP side of the system is self priming, with returns to the tank from pump and all injectors that can get rid of air.

One bit of advice: Avoid touching the HP (rigid metal) pipework and fittings unless you really need to (CH removal or injector replacement etc.) These lines run at 1500Bar (22,000 PSI !) and use high integrity metal to metal seals. There is also a small risk of getting wear debris into the injectors. They have incredibly small holes and valve orifices inside.

If priming does not work, then there is likely to be a cracked or perished hose somewhere.

[3ll]

I have a scanner and app and an obd2 which i can use on my iPhone but it does not show any codes. 

 

i have spoken with a garage who are comin g out today to recover the car and do some diagnostics on it to identify the fault, but they have said already an area of concern is the fuel filter, apparently if ***** quality filters are used this causes the issues i have described. interestingly the fuel filter was changed a while back so thi may very well be part of the problem. 

i will keep the thread updated as i find out more info :) 

[J87]

i have an issue with mine also but i know what it is (not nesseserily the samer issue)

there is a flap in the inlet tube (just past the air box) and that gets stuck closed it regulates air in the intake on start up so somtimes it wont start i have to get out and just lightly shout at the engine while lightly hitting it hard on the top of the plastic part to free it

i need to change it but funds are low at the moment so im stuck shouting at my 2nd morgage at petrol stations occationally

next time this happens take the inlet pipe off ind see if the flap is sticky (may not seem that way) and push it then try to start it

(take the silver o ring off the pipe and pull it off)

[Ryan_Tango]

7 hours ago, 3ll said:

I have a scanner and app and an obd2 which i can use on my iphone but it does not show any codes. 

 

i have spoken with a garage who are comin g out today to recover the car and do some diagnostics on it to identify the fault, but they have said already an area of concern is the fuel filter, apparently if ***** quality filters are used this causes the issues i have described. interestingly the fuel filter was changed a while back so thi may very well be part of the problem. 

i will keep the thread updated as i find out more info :) 

Sometimes it's the fuel filter housing which has not been put back right (air tight) or even the housing could be damaged, when I changed my dads it was fine for months then suddenly one day it wouldn't start but it was due to the housing had broke with a slight crack on the seal.

[3ll]

bit of an update then. 

 

Got the car recovered to a local ford specialist garage, first they managed to get the car started however noted straight away that A: fuel was spraying out of the bolt on injector 2 and 4, however this appears to have been down to them not been tightened up to the correct torque. and B: there was very little fuel going through the fuel line from the filter to the pump, They suspected this was due to a low quality filter been fitted and / or the diapham not been replaced during this process. 

 

They have fitted a genuine Ford fuel filter and made sure that the air was bled from the system, they have as  mentioned also tightened up the injector bolts to the correct torque. 

The car appears to be running fine now, if anything it seems a lot more responsive and quicker on acceleration also. The garage did say that they would investigate further should I have any more difficulties but for two days now its been running fine. 

 

Im hoping thats it sorted(for now until the next issue comes up!)

 

So, if anyone else is reading this and has similar issues to what I described, check the above, it may save you time and money in the long run, oh and if you get a service done like I did, make sure the garage dont fit ***** quality parts! lol 

 

 

[Stoney871]

It is often a problem if non oem filters are fitted.
I believe oem filters always come with new seals whereas non oem do not.
Seals should always be replaced if disturbed as they don't reseal properly.
With my previous Focus (1.8 tdci) I had fuel pressure problems that came down to a dirty filter.
Unfortunately the fuel filters aren't changed on an annual service but I would strongly recommend that they are changed to save trouble further down the line.

Sent from my SM-G930F