This is my third attempt cranking, this time getting a fuel rail pressure readout. No start though again...

20 minutes ago, MikeyTDCI said:

I have added a screenshot of the live capture. When the ignition goes on, you can see the fuel pump rise. And then the RPM rise, when I crank. But the whole time there is no reported fuel pressure.

Also, thanks for reiterating. It's the correct interface, I got it yonks ago on recommendation from the Forscan website. It wasn't working properly before, due to group policy on my laptop.

Thanks, it’s just that I have seen so my posts that start looking at various single issues that in the end come down to cluster or BCM/Fusebox issues in the end.

1 minute ago, RL123 said:

Thanks, it’s just that I have seen so my posts that start looking at various single issues that in the end come down to cluster or BCM/Fusebox issues in the end.

Yeah I am going a bit crazy with this issue. It's my partners car, and our usual mechanic is fully booked. We live in a small rural village, so nearest other garages are 40 minutes away. Problem is whilst he's a great mechanic, he isn't very tech savvy so doesn't use Forscan etc. So I am left to diagnose the fault with Forscan as a tech savv/computer engineer, with an automotive qualification from years ago... I am glad it's not my own car.

Did you prime the fuel filter properly?

There's no tank pump on these sp they need manually priming after a filter change.

6 minutes ago, MikeyTDCI said:

 I am glad it's not my own car.

That's how I feel about most of the cars on here!

1 minute ago, TomsFocus said:

Did you prime the fuel filter properly?

There's no tank pump on these sp they need manually priming after a filter change.

I have a draper, priming kit with the PSA/Ford connectors. I took the oubound feed from the tank, to the filter and filled it up. Car started after a delayed crank, took it for a spirited drive and about five minutes in, the engine malfunction popped up and car cut out. Then had to keep doing the key off, second gear and bump to get me home.

Hmm, should have primed ok then. 

Definitely need to get it running again to rule out the possibility of any air in the system before measuring the fuel pressure.

If it was mine I'd give it a sniff of EasyStart or deodorant in the intake but obviously that's not manufacturer recommend and done at your own risk.

1 hour ago, MikeyTDCI said:

I have a draper, priming kit with the PSA/Ford connectors. I took the oubound feed from the tank, to the filter and filled it up. Car started after a delayed crank, took it for a spirited drive and about five minutes in, the engine malfunction popped up and car cut out. Then had to keep doing the key off, second gear and bump to get me home.

Did you try whacking the dash above the cluster when the malfunction occurs? 
if it comes back to life, you have the awnser, if not it is possible it might still be but worth a try.

it worked on my son’s 2008 ST

9 minutes ago, RL123 said:

Did you try whacking the dash above the cluster when the malfunction occurs? 
if it comes back to life, you have the awnser, if not it is possible it might still be but worth a try.

it worked on my son’s 2008 ST

Yeah I know what you're saying, I know it's a common issue across Ford's of this era. I did wiggle the clocks, but no difference. I should be seeing a load of other faults in the system if the clocks are at fault. I might take them out, and do some testing on my workbench.

 

1 hour ago, TomsFocus said:

Hmm, should have primed ok then. 

Definitely need to get it running again to rule out the possibility of any air in the system before measuring the fuel pressure.

If it was mine I'd give it a sniff of EasyStart or deodorant in the intake but obviously that's not manufacturer recommend and done at your own risk.

I think tomorrow, I am going to try priming again. I was thinking once it's running, maybe just crack off the bolts at the injectors to see if there's any air in the systems?,

I don't recommend cracking off injectors on a common rail diesel personally.  The rail is self-bleeding anyway.  If there's any air trapped, it'll be in the low pressure side.

On 7/15/2023 at 7:35 PM, TomsFocus said:

I don't recommend cracking off injectors on a common rail diesel personally.  The rail is self-bleeding anyway.  If there's any air trapped, it'll be in the low pressure side.

You mentioned something about a fuel regulator earlier in the thread. I am struggling to find any diagram for the fuel system on the 1.6 TDCi/HDI.

1 minute ago, MikeyTDCI said:

You mentioned something about a fuel regulator earlier in the thread. I am struggling to find any diagram for the fuel system on the 1.6 TDCi/HDI.

The pressure regulator (FPR) is on the HP pump on these.  It's not available separately from Ford so doesn't show on the Ford parts catalogue but looks like this.

Can be seen at the bottom of the pump on this picture.

 

Not sure what you're hoping to see on a diagram but the fuel system is very simple on these, it's just really awkward to access.  Basic high pressure system is: HP pump inc FPR>fuel rail inc FPRS>injectors.  

2 minutes ago, TomsFocus said:

The pressure regulator (FPR) is on the HP pump on these.  It's not available separately from Ford so doesn't show on the Ford parts catalogue but looks like this.

Can be seen at the bottom of the pump on this picture.

 

Not sure what you're hoping to see on a diagram but the fuel system is very simple on these, it's just really awkward to access.  Basic high pressure system is: HP pump inc FPR>fuel rail inc FPRS>injectors.  

Is this regulator, what I can hear from the top-left of the engine when the ignition goes to run/is switched off after a malfunction?.

1 minute ago, MikeyTDCI said:

Is this regulator, what I can hear from the top-left of the engine when the ignition goes to run/is switched off after a malfunction?.

It might be.  Difficult to say from the video though and I can't remember hearing a noisy one before.

6 minutes ago, TomsFocus said:

It might be.  Difficult to say from the video though and I can't remember hearing a noisy one before.

Is it driven off the cambelt, or serpentine belt?. And could you kindly tell me the location of it in relation to looking at the engine?.

7 minutes ago, MikeyTDCI said:

Is it driven off the cambelt, or serpentine belt?. And could you kindly tell me the location of it in relation to looking at the engine?.

Yeah, the HP pump is driven from the cambelt.  It's right at the back of the engine, roughly half way up. 

The rusty part is the pump.  The red arrow is pointing to the FPR.  The fuel rail is the black tube with the rectangular white sticker on it.  The fuel pressure sensor is opposite end of the rail to the pump.

2 minutes ago, TomsFocus said:

Yeah, the HP pump is driven from the cambelt.  It's right at the back of the engine, roughly half way up. 

The rusty part is the pump.  The red arrow is pointing to the FPR.  The fuel rail is the black tube with the rectangular white sticker on it.  The fuel pressure sensor is opposite end of the rail to the pump.

If I take the scuttle panel off, and the EGR cooler pipe. I might have decent access to it.

2 hours ago, TomsFocus said:

Yeah, the HP pump is driven from the cambelt.  It's right at the back of the engine, roughly half way up. 

The rusty part is the pump.  The red arrow is pointing to the FPR.  The fuel rail is the black tube with the rectangular white sticker on it.  The fuel pressure sensor is opposite end of the rail to the pump.

I think you're right about the regulator. Reprimed it tonight, car started, but when running you can hear a solenoid noise, not a good one like it's sticking or something. If I put my hand on the regulator, I can feel it vibrating and it's the source of the really loud noise above.

So I have changed the regulator, but I believe they've sent me the wrong one as the electrical connector is the wrong way, and the solenoid itself looks different. I fitted it anyway, and the car did start easier. But won't idle properly, and cuts out. The part numbers are different as well, can anyone confirm if this difference will matter, or link me to the correct one. I have attached some photos. When I started the car, it was knocking really bad like there was air in the system, and when it cut out the solenoid was making the same noise as the old one, but not as bad and stopped shortly after.

Yes, that's the wrong part.  Needs to have the same part number.

Fit To CITROEN PEUGEOT 1.6 HDI D FUEL PRESSURE REGULATOR CONTROL VALVE0928400607 | eBay

5 minutes ago, TomsFocus said:

Yes, that's the wrong part.  Needs to have the same part number.

Fit To CITROEN PEUGEOT 1.6 HDI D FUEL PRESSURE REGULATOR CONTROL VALVE0928400607 | eBay

That looks better to me. Do you know why this one won't work? Bar the slight length difference, it looks totally the same to me.

1 minute ago, MikeyTDCI said:

That looks better to me. Do you know why this one won't work? Bar the slight length difference, it looks totally the same to me.

They'll be different internally.  Designed to regulate different pressures for different fuel pumps.

1 minute ago, TomsFocus said:

They'll be different internally.  Designed to regulate different pressures for different fuel pumps.

Cheers mate, I've ordered the one linked. Looks identical to my old one, I'll send the other back. Interestingly they did link me to the supposed "correct" one, but it appears to be even worse than the one they sent. Check it out https://www.ebay.co.uk/itm/385122353452

3 minutes ago, MikeyTDCI said:

Cheers mate, I've ordered the one linked. Looks identical to my old one, I'll send the other back. Interestingly they did link me to the supposed "correct" one, but it appears to be even worse than the one they sent. Check it out https://www.ebay.co.uk/itm/385122353452

That link is the same as the new one you got.  It's the top number that matters, not the bottom one.

13 minutes ago, TomsFocus said:

That link is the same as the new one you got.  It's the top number that matters, not the bottom one.

Yeah I ordered the one you sent. I'll get it fitted tomorrow when it arrives, and hopefully that is the end of this fiasco and I can call this resolved. What a headache.