Ford Focus TDCI Zetec 2009 - Starting problems

[Georgiec8]

Hey all,

I'm loosing the will to live. I've had problems with my Focus since before Christmas and various garages, an MOT failure and hundreds of pounds later...I'm still unsure of what the issue is.

Every morning, the car won't start. If I do finally get it started it'll run all day. Turn over is fine, just doesn't fire up.

I've already done the following work:
- Changed battery
- New leak off valves/pipework (All were leaking, I suspect for a long time. MOT failed because of no.4 leaking, found out yesterday 1-3 also leaking. Got it fixed and was told "that's it, problem solved"..get in the car this morning to find it not starting again)
- Glow plugs 'checked' by garage(Initially thought this was the problem due to the weather but it's 10c today, so should start regardless)
- Fuel tank cleaned and examined for leaks with no leak found

Can I use EasyStart considering I think the glow plugs are actually working?

I'm very far from a mechanic and I need some suggestions so anything would be really appreciated.

[E-bmw]

What does it start like when it eventually starts?

What does it run like when it starts?

Have you had the fuel pump checked?

Have you had the fuel filter changed?

Have you had a compression test done?

Diesels are relatively simple, if the right amount of fuel is there at the right time & if there is enough compression, they start.

[Georgiec8]

E-bmw said:

What does it start like when it eventually starts?

What does it run like when it starts?

Have you had the fuel pump checked?

Have you had the fuel filter changed?

Have you had a compression test done?

Diesels are relatively simple, if the right amount of fuel is there at the right time & if there is enough compression, they start.

It runs absolutely fine once it's going. I have found that it's started and cut out if I don't rev it hard. Once it stays running for 30 seconds, it runs fine all day.

Fuel filter was changed about 3 weeks ago. They've checked the pump and it was fine.

I haven't had a compression test done actually.

[E-bmw]

In your OP you say "New leak off valves/pipework" pardon my ignorance, but what are leak off valves?

Everything you say in your latest answer is telling me fuel isn't getting there straight away when you try to start.

When you turn on the car can you hear the fuel pump (near/in the tank) start up for a few seconds to prime the system?

When you had the fuel pump checked did they do a leak-off test to check the fuel wasn't draining back to the tank.

[Mr2Mike]

Sounds like a possible air leak somewhere in the low pressure side of the fuel supply.

[E-bmw]

That would do it too, but would quite possibly be coupled with a fuel leak which would much more likely be smelled/seen and so easier to diagnose.

[mighty kitten]

Pretty much every overnight non start I’ve fixed due to chafed plastic fuel lines has never leaked . Seen a lot of fords with pinholes in the return side due to rubbing , c max springs to mind where the pipes come around the engine mount area on the offside

[ford2210]

Have you changed the fuel filter ? They’re becoming a common fault in causing non start even showing low or no fuel pressure when cranking

[Georgiec8]

Thanks for all the advice!

Fuel filter has been changed, few weeks ago.

After finding that the injector leak-off pipe was leaking (and having it fixed) the car still didn't start the next day. I got it started with Easy Start and took it back to the garage and left it over night. I was so sure that this had something to do with the glow plugs and sure enough when I pushed them to check them manually it turns out all 4 glow plugs are knackered. Now my confusion comes from why this would make a difference? It's not exactly minus temperatures at the moment but if all 4 had gone, would this be causing my issue?

When they took out the glow plugs they did find some residue in the holes, could this be from the leak off pipe before I had it fixed? Or is it likely I've got another fuel leak?

I'm going to have to wait until the morning to see if the car starts, if it does and it was all down to the glow plugs then I'll be pretty amazed since I keep getting told I don't even need them when it's not very cold.

Intermittent problems are the worst

[Georgiec8]

Just a quick update - got in the car this morning having had the glow plugs replaced yesterday and it started without problem.

Surprised that they could be the main problem but clearly must have had a lot to do with it.