Hi All,

 

On my 04-2004  1.8 TDCI crank no start we pulled out the injectors and re-connected them; non of them sprays any fuel. No fault codes. With an oscilloscope we measure 50V at the injector, so I am guessing the ECU tries to fire up the injectors. The previous garage who gave up said he replaced one injector and refurbished the others, but without coding them. Fuel pressure is ok, crank and camshaft sensor have been renewed. Can not coding lead to a no start? I read many different messages. Attached picture is the oscilloscope representing the voltage to the injector. HELP!:-) 

What code reader was used?
Does demanded and actual fuel pressure match?
What is cranking speed?
Definitely fuel at rail and filter replaced?
On what justification was the injector work done?
You can code the injectors with Forscan and my "research" says that it should still start but would run erratically.
What is the history of all of this, ideas why it suddenly started (failed to start) any recent work, etc?

Nice oscilloscope trace but unsure if it is correct and don't know if piezo or solenoid:
https://markstammersdiagnostics.com/reference-waveforms/diesel-injectors/

There is a 2008 1.8 Ford trace.

HI,

We have used a Forescan and a general code reader.  Yes demanded and actual fuel pressure match. Crancking speed is up till 300 rpm. Yes definitely fuel at injectors and profound bleeding has been done. Filter replaced; no. The car stranded and I have no idea why they changed the injectors. It's been said they changed one, then it worked for 2 miles and stopped, then they refurbished all injectors and it never run again and they gave up, saying it needs a new pump at a cost of 3000,- euro. So I got a challenge to make it work. I guess I'll start coding them anyway as my "research" says it may not start at all because of no coding.On the picture attached you see  the 2nd and 3rd line are desired and real pressure. Other info; while cracking only one injector has a tiny bit of return fuel, the other 3 nothing.

If your graph is what I think it is, I'd say there's possibly something funny.
I don't know which is which but 47200 kPa and 319 with no units, even if units are consistent is 30% low- are you sure they match?
If there's no leakage when injector union is cracked (never done it) then that should drop rail pressure dramatically and flow should increase? - is that what you mean, or have you done a leak off test - there should be some leakage from all with no major differences?
Is there a broken spring in your HP  pump or "glitter" in the filter from pump break up (depending on design, a major issue) I wouldn't change without inspecting

At 3000 rev/min, my values (2011, Delphi?) 
Demanded: 116700 kPa
        Actual: 118700 kPa

At 840 rev/min:
Demanded: 30900 kPa
        Actual: 30800 kPa

You haven't given the pre-history of this but coding is an obvious next step to rule the simplest/easiest/cheapest thing out?

 

Hey hey, 

Thanks for diving in.

If u mean injectors, refering to "units"; they are out, while connected, so I can see if they spray, which they dont.

With the sentence " even if units are consistent is 30% low- are you sure they match?" I dont know what you mean?

If there is no return flow, I assume there is no pressure drop, as the fuel cant go anywhere.

I did do a fuel leak offf test, meaning take of the fuel return pipes from the injectors and saw that only one throws out some diesel, the other 3 dont while cranking.  Thanks for your values, but thats for a running engine I dont go higher than cranking RPM's; 300.

 

 

 

 

 

 

 

 

For units, I mean that one trace shows kPa, the other doesn't

One trace is 47200kPa (which is significantly higher than my idle reading!), the other is 319 but the units are not given?
Even if 319 is actually 31900 kPa it is still 30% different?
Always best to check - could be powers of 10 out but of course, I may be wrong (Forscan table detail gives units, graphs can autoscale)
Did you have the injectors connected to the rail when out of the cylinder?
I'm unsure if there will be return flow back to the tank at cranking speed, but if there's no spray pattern then it obviously won't start.

Have you coded the injectors yet, to rule that out and after the unjustfied injector work, did you witness them being tested i.e. do any of them work correctly and still no history leading up to this unless it just "came from nowhere" (just sayin!)

Hi i have another video in which the live fuel pressure goes at and above 300 bar, to my knowledge good enough but you have a point that I overlooked yes, it is lower.   Yes the connectors are connected to the rail. I kindof got the car for free after the garage gave up so I wasn't witnessing their actions. There  is a paper of one injected been tested and proven ok. ASAP I will code the injectors. And before a lot of action has been taken to bleed the system.   AI is telling me now that the fact I have zero return on 3 of my injectors is a sign that the "refurbished" injectors are faulty. Even if there is no signal or wrong signal it should drip a bit of return it says.. any ideas?

In general, if the filter hasn't been changed, I'd change it to rule that out, just because, it's my Fuel Problem Rule (yet again, still waiting for history of all of this, when was it last changed?)
Then do your coding, just to rule that out.
I'm concerned about the "efforts at bleeding" - is there an air leak, is this the filter where the seals can be put back wrong, giving air ingress?
If injectors are delivering nothing then obviously it won't start.
Which injector was tested and found good (looking for evidence here, again)?
Suggest doing the cheap basics and testing for no air leaks and some delivery from injectors plus getting demanded and actual rail pressures closer?
I'm now at the limit of my suggestions...

Hi Thanks. UPDATE; all injectors were stuck either caused by gasoline in tank or faulty fuel pump. Found a new pump. They say you should also renew the high pressure pipes , cause little parts may be in those. They seem expensive and not available, any clue? picture is what came out of filter.