My poor van

[chrisw2214]

Hi there I have a 2003 transit 2 litre tdci the 125 hp one I lent it to my brother who killed it for me 5 weeks ago since then I have been pulling my hair out to fix it so far I have replaced the pump cleaned all the swarf from the tank and cleaned out the lines had 4 new fuel injectors have checked my timing have bled the fuel system have fuel at the injectors but the van still won't run I am at my wits end with it and don't know what else to try or to check any one local to gu46 or anyone have any ideas how to fix my van I'm £800 in and still no results I love the van buy is just giving me a constant headache have also swapped the fuel rail and pressure sensor for a spare I had also checked compression and have 18 bar at each cylinder

[amlav]

Crankshaft sensor maybe ?? Try spray a bit of Eazystart (or equivalent ) in to the inlet manifold and see if it tries to fire up . If it does than keep at it till it fires up properly .
It could back fire a few times while spraying .
If it doesn't than it would be something else . Not sure if injectors/pump have to be coded on a mk3.
If compression ok on all 4 cylinders all it needs is fuel and air and timing signal to the injectors .

[chrisw2214]

It fired up after I fitted the 4 injectors then ran with a misfire down the road and very smokey then I turned it off and went to have a look the next morning and it wouldn't start hasn't started since it will go on easy start but won't carry on running when I stop spraying would crank sensor not put a code up ? Or is this a common thing ? I have changed injectors previously without coding but only 2nd hand never new like this time I don't have a machine that will code them hoping it has to be something simple ?

[chrisw2214]

I have fitted a new crank sensor and have a rpm reading on the diagnostic machine but still no go keep getting error code p1631 ecm/pcm main relay fault .any ideas on how to check that as it clears out of the system but come back after cranking

[ned]

P1631 Main Relay Malfunction (Power Hold)
Doesn't this code come up when the battery is low or excessive cranking?. N

[ned]

Have you coded in the injectors now? The early tdci's have an injector control module under the dash on the drivers side separate from the pcm (ecu). N

[chrisw2214]

I don't have a machine that will code them how would I find the module to know if I had one and do you think coding would stop it starting as it ran intitally when I fitted the new injectors but ran very badly and the next day would start

[ned]

You can code in the injectors with this
http://m.ebay.co.uk/itm/Ford-F-Super-Di ... nav=SEARCH
I would code them in and get the battery tested before anything else.

Your van will have a ICM, pop your head under the dash above the accelerator (rhd) and you'll see it. N

[chrisw2214]

I have the battery on charge and it's full of life spinning over very fast and nearly runs but just won't fire so you think coding injectors could be my fault ? Would I need to code the pump as well ?

[chrisw2214]

Had a phone around and have borrowed a g scan now and programmed the injectors in firing order 1 3 4 2 it's still cranking over but now getting these codes come up

[ned]

So there coded in firing order nit cylinder order that's good to know Pump is just a dumb pump no need for coding. N

[chrisw2214]

Still won't run though any ideas what voltage should reach the injectors ?

[chrisw2214]

Have removed the sumo and found alloy swarf any ideas on if that's a piston ring or big end she'll or something ?

[ned]

What actually happened when the van died?

The 2 codes you have point to pump/injectors have they been cleared since you replaced the pump and injectors?

If the 2 codes are fresh then I would be retracing my steps and checking all pipes and connection are good and not allowing air in or leaking, is the new fuel filter the correct one, when you have been trying to start the van have you got enough fuel in the tank (it'll need mire than 1 fuel can full) and have you been filling the fuel filter every couple of attempts.

You say you have fuel to the injectors, how do you know? N

[chrisw2214]

I wasn't driving it when it died I had lent it.to my Bro who said it just stopped but that's all. Not much help really I have 30 litres in the tank which is fresh I put in there after cleaning the swarf out. The trouble codes cleared out but still no joy. I actually have by passed the fuel filter and tank and made up my own clear fuel line with a gravity feed straight to the pump intake and it drinks the fuel but still won't run I know the injectors are getting fuel as when I cracked the pipes off they spray diesel out into the bulkhead thats why I'm so clueless as to why it doesn't run