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Thread: 1.6 TDCi - Knocks after 2700rpm Reply to Thread
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Topic Review (Newest First)
01-23-2013 01:23 PM
Carl0s CASE CLOSED!

Tooked the valve cover off today, and founded out that 2 cam followers had slipped away from the cam / valve and were klocking around. So, atleast 2 busted followers, totaled cam shaft and possibly few bended valves... Il guess ill just try to find whole cylinder head as used part.

"Funny story" the guy from who i bough my injectors, had exacly same on his parrents HDi... Were knocking (tho, that one knocked all the time), and when he took the valve cover off, 2 followers had slipped away, and few bended valves.

He took the head to machinery for valve change, and when he got it back, he noticed that _all_ of the followers had loose bearings... New ones are 40€ each, so he just bought whole engine from parted car...
01-22-2013 10:37 AM
Carl0s Took some videos, first one idling hood up, second one is from the inside (earphones recomended), you can clearly hear the knock after 3000rpm

http://www.youtube.com/watch?v=pZw8d...ature=youtu.be

http://www.youtube.com/watch?v=rpCeG...ature=youtu.be

Any ideas ?
01-21-2013 03:24 PM
Carl0s Edit: sry, doublepost
01-21-2013 03:03 PM
Carl0s Well, got the injectors changed. used my BT-OBD to monitor the Commonrail preasure after shutdown, and it went nearly imediatly to ~4bars, so i just released the rest of it from the injector pipes.

The injectors came out nicely when you losened the fixing bolts, and gave it a nice litle spin from the starter.

There was also nice suprise, injector holes 1 and 3 were full of "sealant glue"... *golf clap*

but anyhow, changed the injectors, and the problem stayd the same. Still knocking after 3k rpm... Tho, now it starts up way better, and pulls way better. Also, i think the commonrail preasures have gone up from ~600bar to over 1000bar...

Can anyone tell me for sure, does these injectors require coding?!

So far ive heard:

-All TDCi injectors after -03 need to be coded. Otherwise the car gives out engine error light, goes to limp and wount rev over 3k

-No need to code, just PCM reset

-No need for coding or reset, ecu will learn the new injectors by its own.


Well, gues what... i only changed the injectors, and nope, i got no limp, no engine light, everything works nicely apart the knock... what got me thinking, if these indeed require coding, and someone has previously done somehting to the injectors whitout coding, could that be the issue. Also, could it be that it requires coding, but doesent show it anyway?

And last, tried to eyeball the injectors, and i could not find any "code" from them that would mach the sayd 8 digit description... :/

Like here you can see the 8 digid code: download/file.php?id=2634&mode=view

But mine, new and the old ones has 9 digid code instead... ?
01-20-2013 02:41 PM
Carl0s Hey, can anyone tell me for sure, can i use F-Super USB adapter, and Formidable to code the new injectors for the 1.6 TDCi Focus? All info that i can find is for mondeo, but nothing for focus... :/
01-16-2013 10:56 AM
Carl0s Did the leakoff test.

Cylinders counted from the timing case, 120sec period

1: 37.5ml
2: 34ml
3: 65ml
4: 37.5ml


I guess there's my problem... :)
01-16-2013 02:06 AM
Carl0s Allright, update:

Friend loaned me a commonral leakoff test kit, so im planning to do a leakoff test today, in order to determine if i should just change the seals, or change the injectors while im at it.

Anyone has any info what the leakoff should be, in example 300sec intervall? I found leakoff test for mondeo (30sec idle, 30sec 2,5k rpm, 30sec idle, etc etc) that should give 25ml whit propper injectors... Anything like that for focus ?
01-12-2013 12:58 PM
Carl0s Well well, after pocking hang-overed brother whit a stick (he's manager on automotive shop that i use as a garage) i got to the garage planing on doing the leak-off test.

I washed the enginebay on wednesday, and havent realy looked under the bonnet after that. Well, gotted the car in, popped the hood and took an eye on the injectors... No need for leak off test. Injectors 1 & 3 were wet from the root, and injectors 2 & 4 were dry ( pics: http://imgur.com/a/32CIS - the numbering starts from the cam belt side).

So, skipped the leak-off test and were planning to check the turbos oil-pipe mesh... but in order to get our hands on it, it seems like you need to take the turbo and exhaust manifold of. But, the on the upper end of the feeder pipe, all looked good. There was oil, and it looked pretty much same as on the dipstick. Also checked the mesh on the vacuum pump, and it was clean.

So, i guess next step is to get the seal kit from the dealer, and mondeospares sayd theyll be in contact if they can get theyr hands on for a propper set of 1.6tdci injectors.

That leaves me for coding? What would be the ideal way? buy my own ForDiag, FSuper, FO-COM or change the injectors, hope it starts and drive it to dealer?


EDIT: Forgot, as you can see, someone has allready done something to the injectors since they are all numbered... Would be nice to know what it might been. The car has full Ford service record, but there is no mention on the book that theyve mendled whit the injectors (but there is notes like "wheel bearings changed etc etc)

EDIT2:

Or what do you think? Should i just buy the seal kit, and clean the injectors, witch saves me from recoding them (i got industrial ultrasonic cleaner at work that i could use to clean em) or buy new used set?
01-11-2013 04:30 PM
Carl0s Allight, another update.

Just did some more testing on the parking lot. If you slowly raise the revs, it doesent knock untill 3k rpm, but if you stomp it from the idle, and release the gas somewhere around ~2.5k, it makes the knock on throtle release. You can only hear it for a brief moment but its there.

So over 3k and when you stomp it like they do in inspection, it knocks... So, this is injectors or ?
01-11-2013 06:44 AM
Carl0s Hoblaaaaaa!

Found someone had exacly the same problem! http://www.tdocuk.com/viewtopic.php?f=41&t=5329


Too bad that they never had any cloasure... so... what do you think? Suddenly the predetonation is back in the game... :)
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