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Old 09-20-2013, 09:07 AM   #1
JRichens
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Focus 06 1.8 TDCi - Limp Mode Error P0191



I bought the car in March 2012 at 103,000 miles – 1 owner before me.
It’s now done 141,000 miles.
The car had a Viezu performance remap March 2012. (They are a highly reputable company who are re-sellers to about 300 UK garages, had before & afters all done on rolling road)
The remap brought the MPG up to high 60’s low 70’s and drove very smoothly and have not had any problems since.
I’ve spoken to them about the problem (Error Code P0191 Fuel Rail Pressure Sensor) and they stress that they do not touch anything to do with the fuel pressure or increase the work load on the injectors/fuel rail, they suggested cleaning out the EGR valve, after firstly getting a full diagnostics from a Ford Garage.

Since about 130,000 miles I’ve been slowly noticing
• A gradual reduction in the MPG from low 70’s down to low 40’s now
• Car intermittently going into limp mode (Engine Systems Management light) - (now constantly in limp mode)
• Car pushing out thick black smoke (Got worse and worse, mainly when accelerating)
• Occasionally when approaching a roundabout, putting into neutral and let roll up, engine completely cuts out (lose power steering) refusing to sit in idle revs as you slowly come to a stop.
• Only recently within the last month an unusual Turbo Whistle Noise if pushed above 2,500 revs.
• Sometimes after filling my fuel tank back up and keeping above 3/4 of a tank I irradiated the problem temporarily.
• When it sometimes came into normal running mode, it would not tick over smoothly around 800rpm like it would in limp mode, it would be dropping to 650 sometimes, and barely staying ticking over.

Things done so far
• Diagnostics kit put on (not fords) and found P0191 error (only error).
• Fuel Lift Pump Replaced in tank
• Normal service parts replaced (fuel filter, oil filter, air filter, oil replaced, break pads, tyres)
• Leak off test on injectors done, nothing coming back in, passed the test

Things considering
• Replacing the Fuel Rail Pressure Sensor (which means replacing the entire Fuel Injector Rails)
• Cleaning out the EGR Valve (however analysis data kit shows this working fine)
• Cleaning out Oil Pickup Pipe to the turbo, not giving enough oil to turbo?
• Getting a software update from Ford (not a remap, an update) not sure what this is
• Replacing the fuel pump

http://engine-codes.com/p0191_ford.html
The error code description and Possible Causes can be found here

Any help/advice would be much appreciated!


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Old 09-24-2013, 01:25 PM   #2
JRichens
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I know it's quite an obscure one people, but can any one atleast advise where to start?
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Old 09-25-2013, 09:32 AM   #3
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Fuel Rail Pressure Sensor was the cause.

It is attached to the entire Fuel Injection Rail though on the manifold, so put a second hand one on and the loom was re-wired to release a bit of tension on the Sensor connections.

There where a few other ECU codes that where effecting each other that have been cleared too, now running again with no error code, no limp mode.

Will update if something comes about again though in the next couple of weeks.

Last edited by JRichens; 11-06-2013 at 06:33 AM.
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Old 09-27-2013, 03:17 AM   #4
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Still..
  • A fair bit of black smoke
  • MPG slightly down
  • 'Whizzing' noise when revs get above 2 - 2.5k from middle front

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Old 10-02-2013, 04:03 AM   #5
JRichens
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So, you're telling me no one has any idea/slight clue as to what this 'Whizzing' noise is? There is still quite a considerable amount of black smoke kicking out the back when you put your foot down, it's as if the fuel isn't all being burnt because the turbo isn't doing it's job to help the engine turn quicker? I really don't know.

I've spoken to a few people about it, and they say it could be to do with the Oil Pickup Pipe to the turbo needing clearing out..
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Old 10-02-2013, 06:14 AM   #6
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I could be a huge build up from the over fueling that needs to be cleared out with some driving.

For the noise, you'll need to use an engine stethoscope(has a metal shaft point instead of the round piece) to isolate the noise. Have someone bring the engine up to the noise level and then isolate it using the stethoscope.
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Old 10-02-2013, 08:35 AM   #7
JRichens
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YouTube video of noise below

http://www.youtube.com/watch?v=05iWj...ature=youtu.be

You can hear it at 5 seconds and around 10-12, then sorry, I close the window at 20secs!

Any ideas?

Last edited by JRichens; 11-06-2013 at 06:33 AM.
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Old 10-02-2013, 08:44 AM   #8
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Sounds like just normal turbo spool but not 100% sure with the wind noise in there too. If it didn't do it before then maybe some inter cooler piping came loose. But then again you would notice a lack of power too.
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Old 10-02-2013, 10:24 AM   #9
JRichens
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Turbo Pipes are Common to split in Ford Focus MK2's apparently..

"Seen split turbo hoses many times on these the most common one being the right angled hose that joins the inlet manifold nearest the o/s/f suspension strut top mount. Squeeze the hose and see if a split becomes apparent. Not always visible on first inspection."

Do you think this is also worth checking?
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Old 10-02-2013, 10:34 AM   #10
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I would, it does sound like a boost leak. Have you lost any power? It could be a small enough leak to not be too noticeable in power.
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