Ford Fiesta 1.6 TDCi - Vibration problem

[Wene]

Hello,

I have a vibration problem with my 2009 Ford Fiesta 1.6 TDCi.
The vibrations occur:
• In neutral
• At around 1100 rpm (and also at around 2200 rpm)
• Even when engaging the clutch (gearbox rolling)
I have already tried a number of things, but without success. Here is the list:

Engine mounts:
- Replacement of the 3 engine mounts
- Exhaust mounts OK and no contact with the body

Damper pulley/timing belt:
- Replacement of the damper pulley with a new one → no change, so the original one was refitted
- Belt in good condition

Injectors:
- Injector return test → no fault
- Cleaning of two injectors showing a slight difference in the test

Flywheel/Clutch:
- Monobloc flywheel in good condition
- Replacement of the clutch kit

EGR valve:
- Cleaning of the EGR valve

Sensors:
- Cleaning of the flow meter
- Cleaning of crankshaft sensor
- Cleaning of pressure sensor

OBD (Forscan extended license):
- No DTCs
- Correct injection rail pressure
- Correct crankshaft sensor
- I am unable to access the injection correction values; if anyone can help me with this point as well

Miscellaneous:
- Blocking some pipes (air conditioning, air) with foam to limit their movement

Based on all these checks, I think it's an engine problem, particularly with the fuel injection, but it's hard to believe that given the correct injector return test and the fact that there is no loss of power.

Thanks in advance for your help.

 

[Handy Andy]

Engine carriage - where those mounts bolt to, are they in good order? No cracked arms from the carriage to the body?

Bolts from the carriage to the body ok?

Any particular rattle when you drive on smooth, transition to gravel road - type of rattle - arriving from the floorboards?

Why do I ask?

It may not necessarily be Directly from the engine but as a built-up shake from a resonance from the RPM - long term steady RPM can induce a fatigue failure - torn metal - like a frame member - caused by a harmonic resonance..

The carriage itself mounts to the wheel-well both sides but also to where your control arms and the main cross-member meet. This is towards the rear of the motor and just under the driver and front passenger seats floorpans.

Other sources of the vibration can come from the engine mount locations - like a crack in the frame to bolt where the side mount towards the front of the motor side - where the serpentine is at - can break. You may be able to even feel the vibration travel thru this mount and stop where the break is at - being that the break frees the motor from any form of dampening from that point - so it really shakes like a tuning fork - in that area - due to that specific RPM making it "sing"

And as you carefully place your fingers from the frame bolt areas towards the mount at where the frame to engine mount meet in that area. CAREFUL OF PINCH POINTS - you may be able to locate it - the Frame and engine sides of the mount don't move in sync with the resonating vibration - you can replace the mounts but if the mounting location itself is fatigued - then the cars own ability to be driven is in question - cracked frame or carriage,