My name is Daniel and Im writing from Portugal. After reading lots of topics here, I decided to write explaining my problems and making lots of questions hoping someone can help me.
Resume of problems & questions:
1 - The van had two episodes of serious trouble in injection (one injector stucked on open position I think) , making a very loud engine knocking and being unable to restart the engine for 2 or 3 days (I think that one cilinder got completely flood of diesel.
1.2 - After some analysis, I decided to open the ECU (Visteon DCU-102) and I founded a serious water ingress problem. I sent the ECU to some electronic specialist guys that supposedly repaired the ECU.
After reinstalation of the ECU, the van worked very well and I have done about 1000km in a trip with steep roads on the mountains, all ok.
Some days after the trip, the van started to make intermittent episodes of "ratling" sound from engine. Not so serious like the first related problem, but serious enough to know that the initial problem wasn't go away.
1.3 - Since the beginning (I'll tell you all the beginning of this van later below), the van was in a state of "Limp Mode". I have changed EGR, tested the Turbo, etc and I have not found a solution for the Limp Mode until the ECU was repaired. When the ECU was reinstalled, the Limp Mode just went away miraculously.
Let me tell you that I have Lexia and Diagbox, and it never fire any errors from the Injection ECU, what is very odd (errors from BSI are recorded).
1.4 - With the ratling engine sound, came to the Limp Mode again.
2 - I tried to make the injectors learning procedure in the Diagbox, but it failed:
"Programming failed: not finished (fuel pressure not stable)
2.1- I tried to make the high pressure pump recalibration procedure, but t fails too without any indication or reason.
3 - Because that "fuel pressure not stable" indication, I decided to get more attention through "Measured Parameters" in the fuel page of Diagbox, and I discovered that the "Measured Rail Pressure" is fluctuating a lot, and not concise with the "Rail Pressure Reference Value".
3.1 - I think that's the reason to the Injection learning fail, I'm right?
3.2 - Perhaps that's the reason too for the Limp Mode?
3.3 - I'm waiting for a new Fuel Flow Valve, and I hope that solves that particular problem.
4 - Injection Learning, Injector code programming questions and a brief explanation of the past of this van:
I bought this van with a broken engine, and swapped this engine by another.
The replacement engine came complete, with injectors, fuel pump, etc (the old engine was given to the guy that sold the replacement engine.
After the installation of the "new engine", I never done any injector coding for this "new" injectors, I didn't knew that it was necessary and haven't the Lexia anyway. Beside that, the first runs of the van seemed to be ok, no Rattling or knocking sounds, just the lack of power that now I know be the Limp Mode.
4.1 - Now knowing that, I decided to code the injectors. My injectors are Denso, and unfortunately they don't have the code on the top of the connector, so I asked my mechanic to remove them so I could see the codes.
4.2 - Surprise! (bad surprise), where's supposed to be the Injector reference and a 16 digit code, my injectors have just 8 digits, but Diagbox asks 16 digits to code them. Now what? What should I do?
4.3 - The injectors are the Denso 6c1q-9k546-ac.
5 - The initial cheap van with a broken engine, is now a nightmare with lots of money burned in, and I'm loosing my hope. So I hope some help from you, and forgiveness for my broken English too
Best regards,
Daniel