"Paul Giverin" <paul@[EMAIL PROTECTED]
> wrote in message
news:r8IcOEESkmBIFw0h@[EMAIL PROTECTED]
> An update on the unusual engine problem I've been having with my 2.0
TDCi
> Focus (Pug engine). Someone might find it helpful in the future:-
>
> About this time last year the car developed an intermittent problem when
> the engine was started within 15-30 minutes of having been shut down.
The
> engine would start but idle roughly at about 600 rpm. It wouldn't
respond
> to throttle inputs and there were plumes of black smoke from the
exhaust.
> The dealer said there were no fault codes but changed the EGR valve
> anyway.
>
> The problem happened a couple of more times but throughout the summer it
> was fine. Come winter, the problem re-occurred. I took it to the dealer
> who did a PCM update on the ECU. This didn't make any difference.
Luckily
> the problem happened while at the dealer so the technician could see the
> problem for himself.
>
> They took the car in for a week and ran lots of tests under the
direction
> of Ford Tech services. They authorised a new set of modified injectors
(at
> £1000/set). When I got the car back it sounded like a tractor. The
dealer
> said that this was probably the result of the modified injectors and was
> the price to pay for having the original problem fixed. Unfortunately
the
> original problem was not fixed and the car went back in again.
>
> Ford sent out a field engineer to look at the car. Apparently they can
> switch off each injector in turn and calculate the performance of each
> one. For reasons I'm not sure of, the performance is expressed as RPM.
All
> four injectors should be within a few RPM of each other. On mine,
> injectors 1 & 3 were 300 RPM down on the other two. So two of the new
> injectors (Siemens) were defective. That would account for the tractor
> like clatter at low revs.
>
> They also replaced the throttle body. The technician had wanted to
replace
> it on its first workshop visit but Ford wouldn't authorise it. The
> technician showed me the problem with it. The butterfly is spring loaded
> open but when pu****ng it fully closed, sometimes it would stick in this
> position. The Ford field engineer authorised its replacement second time
> round.
>
> I now believe that the throttle body was the cause of the warm start
> problems and that the original injectors were fine. Its now had six new
> injectors. Thank God its under warranty.
>
> Finally, when it was in for its first visit, the technician had said how
> awkward the glow plugs were to get out. I asked if it was worth me
paying
> for a new set for him to fit, being as they were out already. He said it
> wasn't worth it as they looked fine and they were there for emissions
> reasons more than anything else. When it was in for its second strip
down,
> the technician felt that the 7mm flats of the glowplugs were looking a
bit
> chewed up by now so he fitted a new set FOC.
>
> The car is sounding quiet again now and the next week or so will tell if
> the warm start problem is finally fixed. Fingers crossed.
If the throttle butterfly sticks closed then this would indeed create
black
smoke and no responce to the throttle.
Tim.
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