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TDCI 130 Fuel Pump Change - Difficulty, Tools, Cost


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11 replies to this topic

#1 onj

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Posted 21 June 2009 - 08:41 PM

Hi

Engine just cut out while driving, no warning, diagnosis reveals:

No spray from injectors when loosened on tickover.
TCDI so no primer pump, only likely fault is rail pressure sensor or high pressure pump.
Fault code just low pressure on rail.
Could be sensor but unlikely the fault and looks costly (replace whole rail).

1) Any other tests to confirm fault?

My guess is I need to buy new pump so...

2) Any idea of cost? Any issues with non Ford parts?

3) Is it a driveway job? Any idea how long it'll take an average DIY'er?

4) Can I get away without the special alignment tool (60-80 quid from look of it), and just bodge it on without any risk (my understanding is timing is not a consideration with TDCI because it's electronic).

Thanks in advance.
onj

#2 Adi69

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Posted 21 June 2009 - 08:45 PM

I recently had injector problems and was given a 2nd hand set of injectors to try. When I fitted them, the car wouldn't start. A Bosch machine was hooked up and low fuel pressure fault code came up. The fuel pressure was a tenth of what it should have been. I swapped a couple of injectors around and the car started even though the fuel pressure was a bit jumpy. All this was because the injectors were faulty and leaking fuel back down the leak off pipes

#3 onj

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Posted 22 June 2009 - 03:23 PM

Well I've hooked up via ODB to check fault codes and read:

P0190 Fuel Rail Sensorial Pressure Circuit Malfunction
and
P2291 inj pressure too low (cranking)

Thing is, with injector nut loosened there's nothing coming out, so I'm a bit confused if it's because the pump has died (i.e. rail holds pressure regardless of faulty rail sensor), or if a faulty rail sensor would cut off pressure from the pump (seems unlikely as its mechanical, although I dont know if there's an electronic regulator valve in there somewhere).

Still, any advice / ideas welcome !! I'm thinking the 1000+ to change pump isnt worth the 3000 value of the whole car.

Cheers
onj

#4 Adi69

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Posted 22 June 2009 - 05:04 PM

Is there anyone else you know with a TDCi? Just thinking if you could swap rail pressure sensor and try it.

The fuel filter isn't blocked is it?

#5 onj

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Posted 22 June 2009 - 08:51 PM

Fuel filter is fine, car was actually due for a service soon so no gunk would have for into the pump either. Was able to draw fuel through the filter with a hand siphon ok.

I was under the impression you had to buy a whole new rail not just the rail pressure sensor? Either way, no I dont know anyone with a similar car and quite an expensive gamble :(

According to the guide, when the rail sensor is disconnected the car should just ignore it and start anyhow, raising pressure steadily (i.e. dont leave it running). It wouldnt start when the sensor was disconnected, and no fuel came out of the loosened injector nut (i.e. no high pressure).

Thanks,
onj

#6 graemewelch

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Posted 22 June 2009 - 11:13 PM

try removing the pipe that gose from the pump to the rail. see if your getting fuel, if it is the pump that is failed then youll need new injectors and possibly tank and fuel lines as theyll be full of metal particles. if in doubt check it check out properly. dont just chuck money at it. but the answer to your question, yes its very easy to change the pump. dont even think of trying to save money by removing the timing chain cover, itll cost you more than buying the correct tool. yes you are right theres no timing with a tdci

#7 fes_786

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Posted 23 June 2009 - 12:19 AM

get the rail pressure sensor from a scrappy


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#8 onj

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Posted 04 July 2009 - 08:29 AM

Graeme,

From your experience, what's the likely cost of getting this fixed? I can DIY whatever's necessary, take to a specialist or get fraud to take a look.

Deffo no fuel getting to rail, a loosened nut on injector doesnt leak a think on cranking. Is it highly likely injectors are knackered too?

From what I've seen:

~1000 for fraud to fix the fuel pump (includes changing the lines around pump also).

650 for a brand new pump with lines, not found a better price for new.

~200 for a set of injectors from someone off the board here.

I dont have the £70 tools to remove pump if I DIY, but do have odb software to code injectors if I DIY those.

at ~84k the car is probably due for new clutch soon, and needs a service and a few small things done anyhow.

Cheers
onj

#9 swordtail

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Posted 04 July 2009 - 08:46 AM

I think Graeme said crack the nut BEFORE the fuel rail to see if you are getting fuel.If you do it at the injector if one is stuck open the fuel will just go straight into the cylinder and will not show at the nut you cracked open.If that makes any sense.
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#10 graemewelch

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Posted 04 July 2009 - 11:19 AM

cheers swordtail. you saved me a bit of typing there