Zetec 1.4 TDCi Diesel mk6 facelift (2007): Engine Misfire, Intermittent Fault

[EpicFishFingers]

I used this site: http://ukbookshelf.co.uk/fordv

£5 for the code and it actually worked too, not bad.

MOT cost £195 in total due to white indicator bulbs, a brake light out, and a replacement exhaust :/

But hey, 12 months MOT with no advisories is good for a sale, right?

[EpicFishFingers]

Hey guys, final edit

 

I sold the car today, as is. Took a while to find a buyer but they took it off me for £650, which I'm pretty happy with.

I'll never buy a diesel Ford again unless I'm immediately blanking off the EGR system. It was a fun car, shame it was a lemon. Sad to see it go, but glad to be shot of the stress of "is it this part, or that part, or what? Will I get to work today?" etc. Everything pointed to injectors in the end but it's not my problem anymore.

Advice to anyone who suffers similar issues: blank off the EGR valve as a first step, and if problems persist, investigate the injectors, then I guess the fuel rails etc.

[m1tch]

We will probably find the new owner on the forum soon then!

[ccthomason81]

On 05/07/2016 at 3:03 PM, Tdci-Peter said:

That sounds way beyond EGR problems, it just can't do that. You really should try to find out what codes are behind the Error light, it is there to help, not to hinder. Like Ian says, a good Ford garage should be able to track it down, but they are not all good, and can be expensive. Though the car is not that old, nor high mileage, so it should be worth it. It sounds almost worthless if you tried to sell it now.

Major O2 sensor errors will give a diagnostic code, as will the Mass Air Flow sensor.

If the car was actually decelerating, it sounds like combustion was taking place too early, during the compression stroke. That could be a leaking injector, or crankshaft sensor error, or even a pcm error.

Just shutting the fuel supply off (possible result of faulty O2 sensor or MAF), should only cause the vehicle to stop accelerating, and coast.

Seems a shame to chuck away an 8 year old car. Do you have a code scanner? There is loads of advice on this site about them. They are a worthwhile investment for Every owner of a modern car.

Peter.

Hello, 

ive got a 08 Ford Fiesta van, i was on the verge of getting rid of mine until I had a mechanical genius fix it! Yes actually fix it! 

Apparently, the problem is the injector wiring loom. 

He did all the egr, air mass sensor etc...still did it! It turns out that the injector wiring loom wasn't getting the voltage, causing the injectors  to fault. 

Apparently, it's a common problem with this particular model. 

My wiring harnesses where actually damaged and had been cable tied together. 

So, after a year of absolute doubt I had a new injector wiring loom on and it seems like new. No kangaroo jumps. 

Whether it's finally fixed completely(touch wood) or I'm just lucky, I thought I'd share. 

By the way, if it shows any sign of jerking in acceleration get your mechanic to check your injector wiring harnesses for damage. It will come up as a high circuit injector (injector fault)

I'll report back with a update. 

[m1tch]

Glad yours was sorted with a cheap part to sort it, my 1.4 TDCi is currently on around 122k miles and has no issues, its the 1.6 TDCI DV6 engine that has all the issues. Just give the engine a good service, diesel purge through the injectors, new fuel filter and make sure that the belts and tensioners are sorted and it will probably run for many many more miles.

[isetta]

whilst i acknowledge that some of the fiesta 1.6 diesels have problems some do last well. my fiesta 1.6tdci (2007 year with the twin cam 16valve engine) was in my ownership from 1,600 miles to 146k miles. only problems I had were blocked fuel filter causing low fuel pressure fault, but it had been on there for 120k without being changed. and three of the injectors starting to leak around the copper seal at different times, all cured by doing the bolts up tighter. car now in my brothers ownership and on 148k. still runs perfect but one injector leaking around base again, not chuffing, but wet and causes unpleasant smell when heater on. having said that I would be very cautious of buying one of these cars 2nd hand in case it is a problem one , that has just been fixed so that it runs well enough for a test drive and will then cause grief.

 

[m1tch]

10 hours ago, isetta said:

whilst i acknowledge that some of the fiesta 1.6 diesels have problems some do last well. my fiesta 1.6tdci (2007 year with the twin cam 16valve engine) was in my ownership from 1,600 miles to 146k miles. only problems I had were blocked fuel filter causing low fuel pressure fault, but it had been on there for 120k without being changed. and three of the injectors starting to leak around the copper seal at different times, all cured by doing the bolts up tighter. car now in my brothers ownership and on 148k. still runs perfect but one injector leaking around base again, not chuffing, but wet and causes unpleasant smell when heater on. having said that I would be very cautious of buying one of these cars 2nd hand in case it is a problem one , that has just been fixed so that it runs well enough for a test drive and will then cause grief.

 

The fact you have owned it and obviously cared for it through its lifetime meant that its been ok, they are good engines in terms or power and fuel economy, there are design flaws with the engine however its usually the owner who doesn't address the servicing as well as it should be so wouldn't be buying a DV6 powered car second hand. My dad has the Citroen C3 Picasso with the same engine, I warned him not to get it as he does a few shorter trips and only gets the car serviced once a year, so far its cost him to get the DPF regenerated plus around £1000 to replace the oil system.

[forgotime]

My experience with AP diesel. Car FORD FIESTA TDCI 1.4 2006. Symptoms; rough idling, engine management light on, limp mode. When scanned with forscan OBD software resulted in error code P0192 – fuel pressure sensor low output. Took the car to AP diesel for diagnostic at a charge of £90. They phoned me saying all 4 solenoids on my injectors were faulty and would need to remove all 4 injectors for testing at a cost of £400. And if I needed any injectors replacing at a cost of £120 each. At that point I paid the £90 diagnostic test and took my car away. I did not even get a diagnostic test result piece of paper to document the errors to my injectors. When I asked for the results all they said were the injector solenoids were out of normal range. Terrible customer service, they did not even offer to drive me to the train station when I dropped my car there.

Subsequently removed my injectors and took them to Peter Strong in Reading to get them tested at £12 each. He stated all 4 injectors had low fuel output at 2ml per second and the normal output was 4.5-6ml per second at idle. He stated all 4 injectors would need replacing at £175 per injector. No test sheet provided, and did not explain how the injectors became faulty, not a lot of help really.

I was not happy with his diagnosis so took the injectors to LYNX diesels in Reading. He also stated all 4 injectors were blocked and had low fuel output and would charge me £120 per injector to change the nozzles and this would correct the problem.

Solution:

I purchased 4 new nozzles from darwen diesels at £140 including delivery, swapped out the nozzles and placed them back into the car. When testing the old nozzles I found only 2 of the 4 nozzles were blocked! As I had 4 new nozzles I replaced all the injectors with new nozzles. When I used forscan again I had the same error code P0192! After some googling, a weeks’ worth I found an article which said the connector to the fuel pressure sensor deteriorates and can cause this error code. After testing the connector with a multi meter I found the problem. Purchase a used second hand wiring harness of eBay and solved the problem!!!

With the change of injector nozzles the car idles quieter and the fuel economy became better, so the blocked nozzles did effect the cars performance, economy and noise levels. A job worth doing.

So far after 1000 miles the car is running perfectly.

[Tdci-Peter]

On 13/05/2017 at 2:27 PM, forgotime said:

When testing the old nozzles I found only 2 of the 4 nozzles were blocked!

How did you test the nozzles, as a matter of interest?

The Diesel specialists sound very poor, spouting a lot of nonsense, it seems.

If the engine needs 4.5 to 6ml per second of fuel to idle, it will stall at 2ml per second. What they need to be looking at is the injector drive pulse width. What happens is the ECU just adjusts the pulse width, putting more or less fuel in, until the idle speed is right. So the fuel rate is utterly meaningless unless they relate it to the pulse width.

My car will "idle" in gear, up quite a good gradient, pulling a heavy load. And provided gradient changes are not too abrupt, it maintains an almost constant idle speed. All that happens is the engine note deepens very slightly as it works harder. Obviously a lot more fuel is being put in to do this.

With the diagnostic code pointing directly and simply to the fuel pump, sensor or connectors, it seems odd they did not check this first. Instead of going straight for the expensive (more profitable?) injectors.

You did well to ignore most of what they said, and find the real fault. Good work, and a nice report.

 

[Lewis123]

I read through this yesterday, I have the exact same problem with my car you’re describing. I read someone’s comment advising to remove the MAF sensor, and considering the injectors aren’t at fault it would make complete sense that a faulty maf sensor would cause almost robotic judders during acceleration/idling. I removed the MAF sensor this morning and I’m pretty sure it’s fixes the problem, early days yet but I am very thankful as this has been a very stressful few months of not knowing wether to scrap it or wether I was going to break down! Thanks a lot 

[Peste]

The issue is, one of the VDO Siemens  injectores are in short-circuit, same happens to me, it only shows faulty code wen car goes safe mode and start working in 3 cilinders, and can take like 7-8 years to happen. Until than you strugle to find why car sometimes fail for 1 second. And dont use VDO Siemens refurbished injectors, 90% of the time they have the same issue unless they have a new solonoid, happen to me, the injector they change its in worse condition than mine. I buy a new one to fix the problem.