We have a 2009 Fusion 1.4 tdci we were going to sell on as it just sits on drive and is never used anymore.

Code read the car it comes up with zero faults no eml on nothing.

When we start the car from cold it runs rough lumpy like an injector has failed but if we leave it about 20 minutes it runs absolutely perfect.

So my first thought was water temperature sender is faulty telling the car it is hotter than it is, So new one fitted and no difference.

This car has had new fuel filter all the injector seals and other seals on rocker cover replaced, it has had brand new fuel pipes which go across from the filter to the pump, it is the one with the manual hand pump to pump diesel through after a filter change.  I have cleaned the MAF sensor and still it is lumpy when cold and I mean very lumpy like it is running on two cylinders.  

I even when it was cold running lumpy removed air filter and unplugged each injector individually and number 1 (cambelt end) made zero difference but 2 3 4 made the car cut out.  But when car is warm and running sweet if I remove number one connector the car runs on 3 cylinders, plug it back in and runs on all 4 again perfectly which tells me along with no fault code the wiring and injector is working fine. 

I am pretty good with mechanical problems usually but this one has me stumped! I can see through the fuel pipes and look for air and no nothing unusual just fuel flowing.

So if it was 02 sensor fault or MAF sensor surely I would have a fault code?

Any help is appreciated.

This model/engine won't have an O2 sensor so we can rule that out.

Sounds like a duff glowplug to me.

Had this myself, but also had 2 bad injector seals at the same time which threw me at the time.

As you say you have done injector seals, then As Tom suggests i would suspect glowplugs.

Always wise to check them whilst top end is stripped, I think they should read at around 1 ohm resistance on a DVM, can be measured in situ - just pull the connector first.

If you decide to do them and need any advice, comment and i will tell you the method i used to remove safely without snapping.

19 hours ago, fullwavebridge said:

Had this myself, but also had 2 bad injector seals at the same time which threw me at the time.

As you say you have done injector seals, then As Tom suggests i would suspect glowplugs.

Always wise to check them whilst top end is stripped, I think they should read at around 1 ohm resistance on a DVM, can be measured in situ - just pull the connector first.

If you decide to do them and need any advice, comment and i will tell you the method i used to remove safely without snapping.

Hi and thank you, Ok I removed all the heater plugs, I left them swimming in WD40 for a few hours then ran the engine to warm it up, then tried my luck and they undid ok.

Tested them and got .3 ohms on two and two were dead which is a huge Yes for me as hopefully you good folk on here may have cured the problem Thank you.

So a set of NGK on order and whilst I wait there delivery I will be going back out to it and testing the wiring to ensure that is all good too.

Will report back when new plugs are fitted. 

Thanks Again. 

Good stuff.

You did well getting them out, MANY fail.

I checked my old pics and yes they should be around 1 ohm resistance - on my fluke dvm thats what they measured, ensure you compare the new ones to the old ones for resistance comparison as 0.3 ohms is probably down to meter calibration, wrong resolution or using an analogue meter.

Important thing is you found the (wrong uns) 👍