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Fault diagnosis, Please help!

Transit Mk3, 4 & 5(smiley front) Forum. All Transits 1986 - 2000

Fault diagnosis, Please help!

Postby andygee1138 » Sat Aug 05, 2017 6:54 pm

Hi all. After some motorway driving then a rest my 2.5Di Mk3 (1995 engine, bosch pump) is misbehaving. It feels like a misfire would in a petrol motor, High reve arent so bad but pulling away or under load she is stuttering. Sounds normal at idle though. I know petrol engines but dont know where to start on a diesel. blocked injector perhaps? She was near empty last night and wouldnt start today till I put more fuel in... Crap from the bottom of the tank?
PLEASE HELP! She is my everyday driver!
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Re: Fault diagnosis, Please help!

Postby ricc » Sat Aug 05, 2017 7:13 pm

fuel filter might be blocked with crap from the tank.
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Re: Fault diagnosis, Please help!

Postby andygee1138 » Sat Aug 05, 2017 7:25 pm

New filter or can it be flushed? Have a yellow screw cap on the bottom?
Thanks for the reply!
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Re: Fault diagnosis, Please help!

Postby andygee1138 » Sat Aug 05, 2017 7:36 pm

New filter or can it be flushed? Have a yellow screw cap on the bottom?
Thanks for the reply!
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Re: Fault diagnosis, Please help!

Postby vanfox » Sat Aug 05, 2017 7:45 pm

Guess you've learned a lesson, don't run a Smiley below quarter full....EVER!
Pulls crap from the tank and the fuel swill can let air in.
Start up and bleed the injectors, one at a time, good spurt of fuel, 17mm spanner. Change the fuel filter, all should be well.
Teeshirt.
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Re: Fault diagnosis, Please help!

Postby andygee1138 » Sat Aug 05, 2017 8:01 pm

Right I'll give the bleed a go tomorrow and also get the filter off so I know what to buy. Thanks for the 'quarter tank' heads up! :)
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Re: Fault diagnosis, Please help!

Postby AndyG » Sun Aug 06, 2017 12:43 am

Which injector has the "fuel return" blanking cap :?: (No.1 or No.4)
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Re: Fault diagnosis, Please help!

Postby Keef » Sun Aug 06, 2017 10:13 am

One more and you'll have enough teeshirts for the whole week :lol: :lol:
vanfox wrote:Start up and bleed the injectors, one at a time, good spurt of fuel, 17mm spanner. Change the fuel filter, all should be well.
Teeshirt.

vanfox wrote:The 34 ICH goes quite well, as does a properly set up VV, teeshirt etc.

vanfox wrote:Which ever way you go FFS carry two spare fuel filters 'cos the veg will drag all the sh1t out of your fuel tank which will manifest itself by a loss of power as the filter clogs. Stop as soon as you feel it. Make sure you know how to change it correctly at the road side and fill the new filter with diesel. Teeshirt etc.

vanfox wrote:Go easy on the easystart, a good battery and a whiff should be all you need. (teeshirt).

vanfox wrote:They are LEDs incorporated in the electronics, not interchangeable with bulbs, plus different mounting. Teeshirt.

vanfox wrote:My money is on corroded battery leads. Been there, teeshirt etc.
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Re: Fault diagnosis, Please help!

Postby derv23 » Sun Aug 06, 2017 12:39 pm

:lol: I like it keef.
Strangely I've never had a problem running any of my vans below a quarter tank. Though my fuel gauge is a bit dicky. Not to accurate, plus I think my low fuel light doesn't work, its never came on , even when run low. As mentioned, get the leak off mod done if it hasn't been done already.
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Re: Fault diagnosis, Please help!

Postby andygee1138 » Sun Aug 06, 2017 1:44 pm

This is sounding promising guys! I had horrible thoughts of munched pistons and rings...
Don't even think mine HAS a low fuel lamp... :lol:
Whats the leak off mod? I swapped in the newer Di last year and had to improvise a bit... At present the pipe goes from 1 to 2 to 3 to 4, from there, pvc pipe to a tee from the filter return to the tank return pipe. Have i messed up? :shock:
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Re: Fault diagnosis, Please help!

Postby andygee1138 » Sun Aug 06, 2017 2:28 pm

Ok. Starting to worry now...
Have removed the filter and ordered a new one. Swilled it around and what came out both ends looked clean and the internals look fine. I know that doesnt mean much but...
I then bled the fuel lines to the injectors (the 17mm union to the branch pipe right?) while she was running. when each union was opened the engine ran rough then returned to how it was before. Lots of fuel spurting out so thats ok. However she still sounds like she is running on three, surely there should have been SOME improvement if only briefly? Could it be an injector issue? I know very little about them other than they are mechanical and probably need a puller. Are they servicable? Can I clean them? I have no testing kit either... Am worried they are £35-40 each and I have no idea whats wrong...
Sorry lads, bit of panic now, bit out of my depth... :shock:
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Re: Fault diagnosis, Please help!

Postby andygee1138 » Sun Aug 06, 2017 2:43 pm

Ok, just found this...
viewtopic.php?f=4&t=167771&p=1424237&hilit=clean+injectors#p1424237
No way am I taking those bad boys apart. :cry:
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Re: Fault diagnosis, Please help!

Postby Keef » Sun Aug 06, 2017 5:57 pm

Do the leak off mod first which is just getting a length if leak off pipe and moving the leak off return pipe to No1 injector and the blank to No4 injector to help prevent airlocks.

Try running it with the fuel cap off in case the tank breather is blocked.

If this started when you ran out of fuel then it's very likely to be crap in the system somewhere and it does sound like either fuel starvation or air in the system.

I would try blowing the fuel lines through and if that doesn't help put some clear pipe between filter and Injection pump to check you're not sucking air in.

After that, lift pump is a cheap replacement and worth a try.
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Re: Fault diagnosis, Please help!

Postby andygee1138 » Sun Aug 06, 2017 7:38 pm

Lift pump? It has a mechanical pump on the block?
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Re: Fault diagnosis, Please help!

Postby vanfox » Sun Aug 06, 2017 10:41 pm

Lift pump? It has a mechanical pump on the block? ??

Best if you buy the transit book, 3019, to familiarize yourself with the Di, there's a few on ebay just now.
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