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Old 02-22-2007, 13:24   #1 (permalink)
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TDCI noise when starting..Please help

Guys,

The old mans just bought a 2003 Focus TDCI 115ps Ghia and when it starts it makes a rattle type noise. Not sure what it is. It allways starts and runs and drives lovely. The only problem is this weird noise when starting up. Ive read all the about other crank and fuel pressure probs but these suggest poor starting. This doesnt happen...not yet anyway. It always starts just with a little knocky type noise.

Any ideas?? Should he take it back and get his money back?
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Old 02-23-2007, 01:28   #2 (permalink)
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Re: TDCI noise when starting..Please help

And, it didnt do it this morning when starting from cold???????????????????

Weird!!!!!!!!!

By the wya its a 2004 not 2003
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Old 02-23-2007, 02:11   #3 (permalink)
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Re: TDCI noise when starting..Please help

And, it didnt do it this morning when starting from cold???????????????????

Weird!!!!!!!!! Just spoke to a mechanic and he siad possibly EGR valve or CAT.

Anyone else suffered from these symptoms???

By the wya its a 2004 not 2003
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Old 03-03-2007, 14:37   #4 (permalink)
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Re: TDCI noise when starting..Please help

Does it still have Ford warranty? If so, I'd be taking it in for them to listen.
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Old 03-26-2007, 11:15   #5 (permalink)
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Re: TDCI noise when starting..Please help

Quote:
Originally Posted by arididit
Guys,

The old mans just bought a 2003 Focus TDCI 115ps Ghia and when it starts it makes a rattle type noise. Not sure what it is. ... The only problem is this weird noise when starting up. ......It always starts just with a little knocky type noise.

Any ideas?? Should he take it back and get his money back?
This is the dual mass flywheel (DMF) going through resonance as the engine accelerates throught the critical resonance speed. It can get worse with age as the DMF gets 'slacker' and clatters from stop to stop more as the engine runs up to idle.
There's not much you can do other than buy a new DMF and have it fitted... or live with it!

There may be a calibration upgrade for the ECU from Ford to help accelerate the engine through this speed quicker, reducing the rattle? Checking the TSB's will show if its available.

The engine may sometimes crank, then fire and REALLY rattle like its going to shake itself apart. Mine does this perhaps 1 start in 100. This is when the DMF goes into resonance but there hasn't been enough acceleration for the engine to ge tout of the resonance band, so it remains stuck at the resonant frequency (450rpm IIRC).

If it does this switch it off immediately as the DMF can rattle itself to pieces.

Hope this helps? Steve
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Old 10-06-2007, 15:18   #6 (permalink)
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Re: TDCI noise when starting..Please help

Just found this one, I think I may have the DMF problem.

The TDCI Focus I have on a '53 plate with 52K up just started to make a noise akin to someone banging on a wooden floor in a room above you!!

Recently, when stopping the engine, there has been noticeable clunk as the engine stops.

Anyone have any ideas, could it be the flywheel disintegrating?

Cheers
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Old 10-06-2007, 22:10   #7 (permalink)
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Re: TDCI noise when starting..Please help

The flywheel will only fall apart if it is allowed to get stuck at the 450 rpm resonant frequency during starting. If it does it, turn the ignition off immediately & restart the engine. It shouldn't do it a second time.

The clunk on shut down is normal as the springs in the DMF slacken off. It really isn't a big deal and the DMF will live for many hundreds of thousands of miles as long as you avoid the 450 rpm hang-up.
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Old 10-06-2007, 22:12   #8 (permalink)
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Re: TDCI noise when starting..Please help

For people suffering a rattly/knocky noise on start up the FEAD (ancillary belt) tensioner gets a bit slack with time and can slap about on start up. This makes a knocking noise from the offside of the engine.

Again, nothing to worry about.
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Old 10-07-2007, 12:51   #9 (permalink)
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confused Re: TDCI noise when starting..Please help

To the drastic move this morning the start up the Focus, just to see if anything happened.

Nothing, just normal tickover, even blipping the throttle, normal service.

Left it running whilst did a couple of other jobs then after about 15 minutes, the dreaded 'knock/bang' arrived again but not constant.

No movement of the engine in whilst ticking over.

But when the engine is killed, there are a number of bangs, almost like the exhaust hitting the underside of the car on several occasions.

Oh well, I'll talk to someone tomorrow who may know. I daren't drive it unless I am absolutley confident that all will be OK.
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Old 04-14-2010, 10:18   #10 (permalink)
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confused Re: TDCI noise when starting..Please help

Quote:
Originally Posted by arididit View Post
And, it didnt do it this morning when starting from cold???????????????????

Weird!!!!!!!!! Just spoke to a mechanic and he siad possibly EGR valve or CAT.

Anyone else suffered from these symptoms???

By the wya its a 2004 not 2003
Hello arididit,

Did you ever get to the bottom of this as I am experiencing exactly the same symptoms. Only bought the car last weekend so a bit gutted. Worried that it is DMF as I have been quoted £750 + VAT to get this fixed. I would greatly appreciate a response.

Cheers.
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