Ford Smax TDCI 2.0 2013.

The car will start every morning and I can drive to work and start again with no problems after work but if I drive it anywhere and stop for a while the car will not restart.

Had it serviced and the fuel filter changed.

The only codes in the car are P2002 Diesel Particulate Filter Efficiency below threshold Bank 1. This code comes up when I drive up a hill at high revs causing Engine Management light and limp mode which limp mode goes after 1-2mins.

Changed MAP sensor as easy to change.

Likely multiple issues? (no evidence to change MAP sensor unless I'm missing the point?):
Use Forscan and Vlinker lead (what are you using?)
1 or 2: Check DPF pressure differential (should be under 10 mBar at idle and around 40-60 at 3000 RPM?)
If it is blocked, it may initiate limp mode.

Does your model still have the vaporiser plug (can fail at around 80k miles)

2 or 1: Don't understand why first start, leave during day and return home works and intermediate starts don't unless it's temperature related (is engine still warm)?

Again, Forscan look at fuel rail pressure (demanded and actual) - vehicle is obviously basically OK but something is stopping it from starting (simple check air in fuel line, but crazy as that would be worse overnight?)
More info and any data/fault codes when fails to start (don't switch off) please?

Thanks for the response.

Not sure about the vapouriser.

Did a run today with live data.

In forscan it shows kPa for DPF Differential pressure on the particulate filter.

On the drive at idle it's 0.0 kPA, at 3000 rpm it shows 5.0kPA.

On a drive, I put it on cruise control at 3000rpm and the logs show it's around 5.0 kPa and peaked at 6.0 kPa.

At start up
DPF Max Soot Loading - Inferred Closed - 32%
DPF Max Soot Loading - Infered Open - 20%

After 45min drive
DPF Max Soot Loading - Inferred Closed - 52%
DPF Max Soot Loading - Infered Open - 22%

Fuel Rail Pressure at startup 30800.00 kPa
Fuel rail pressure - desired 309000.00 kPA
 

Sorry, newbie. Not sure if this is what you asked.

Many thanks.

I will try and record data when it does not start.

That is strange.  Those DPF values look fine and not what I'd expect with that fault code. 

Though to get peak DPF pressure you need to be under load, such as going up hill, not just revving at 3000rpm, which is fairly gentle on the flat.

To me (and only to me - I can only say what I'd do if it were my vehicle) DPF readings look fine i.e "zero" (often the readouts go up in discrete amounts) plus the soot loadings appear low.

Of course, they will increase until a regeneration is triggered.

Regarding fuel rail pressures, I get:

114400 kPa at 3000 rev/min (demanded 112800 kPa)

700kPa at idle (demanded 30000 kPa unsure why the difference, may be controlling up to that?)

Is there an extra 0 in your desired as it's VERY  high (if so those values also look OK to me?)

Next step is, as you say, to find readings when it won't start. Likely more data needed such as turbo vane & boost pressure actuator, MAF MAP, temperatures: IAT, AAT, coolant. These are some critical ones I can think of, looking for difference between the start and no start conditions??

Just noticed @TomsFocus has replied so interested in that....

 

 

You need to Live Monitor with FORScan while driving up that hill at high Revs to see what DPF Pressure triggers the Fault Code.

Often when it reaches above 15 kPa a Code will be set, if it does reach that then there is something wrong with either the DPF or its Sensor.

Although I haven't done it, I am assured that your monitoring can be recorded by Forscan.
Always worried about safety as shouldn't try to monitor laptop and drive  - or you monitor whilst someone else drives to your instructions?

Sorry if Grandmothers and Eggs!😉

Thanks for all your reply.

I will do some more live logs going up hills.

Sorry, yes 1 extra 0 in desired. 30900.0

Logs show Fuel Rail pressure at 3000rpm while driving is

FRP 132360.0

FRP Desired  130450.0

Thanks

Yes, I left the laptop on the passenger's seat, when I stopped driving hit stop and then you can save the logs to be opened later. You can then slide back and forth through the graph and click on the lines to show values.

Good, can't be too safe (and suspect using laptop would be treated legally like mobile phone use)

Again, at the moment, those fuel pressures look like demand=actual.

More data PIDs needed when normal and when fault is there?

Hi MJCotswold, all. Did you get anywhere with this problem with your S-Max please? I have a 2011 2.0 TDCi and I'm having exactly the same problem. It will start from cold, no problem, but once warmed up it turns over but takes a number of attempts to get it to start (it is a laboured turn-over when trying to start when warm, starts really easily when cold). Cheers. 

1 hour ago, JRobbo said:

Hi MJCotswold, all. Did you get anywhere with this problem with your S-Max please? I have a 2011 2.0 TDCi and I'm having exactly the same problem. It will start from cold, no problem, but once warmed up it turns over but takes a number of attempts to get it to start (it is a laboured turn-over when trying to start when warm, starts really easily when cold). Cheers. 

That sounds as if the starter motor is faulty, if it's not turning the engine smartly when hot.

Been a long time but thought would update.

Garage changed fuel rail sensor and crank shaft sensor which fixed the issue.

Thanks all.

1 hour ago, MJCotswold said:

Garage changed fuel rail sensor and crank shaft sensor which fixed the issue.

 

From above, your fuel rail pressure sensor appeared to be fine - what was their justification for changing that (were both changed together or which was changed first with what results?)
It looks like the crankshaft sensor may have been the issue and that may have been indicated if live data had been monitored whilst attempting to start in the fault condition.
Whilst it's great that you have come back and told us the fix (Thanks!), it's the real diagnosis and detail that would make the difference for anyone having a similar problem, like me 😉.