MK3 2.5d: Engine stops and wont start

[stieevo]

Hello guys,

my 89 Transit Van with 2.5d Engine and Lucas injection gives me a headache. (I am just mooving my appartement, so its really a pain)

Mostly it runs super smooth, but sometimes, so far always when its hot outside the engine stops out of nowhere.
Following things happen:

1.) Motor starts run on low RPM in idle, the car is shakeing
2.) When I push the throttle, nothing happens (or when lucky, it takes a while to react)
3.)Motor stops completely at some point

To restart the Engine, I had to use Break-Cleaner to spray it in the air-intake. This helps not too much when engine is hot, it starts but it fails again soon. If engine is cold, all is fine after a little spray.
My battery is full, and the starter is in good condition. I guess there is not enough gas injection. But how is it controlled on this van?

Please help, I dont even want to try to go to the dealer as I heard bad stories.

Thanks a lot!

Stefan, Austria

[Keef]

Try the leak off mod

[twin wheel camper]

First thing I'd do is next time it's playing up take off the diesel cap and see if there is vacuum in the tank, it sounds as if it's starving of fuel and the breather in the tank might be blocked.

[Jim Archer]

One of the fuel inlet side fittings on either the fuel filter or the pump is leaking and drawing in air.

Jim

[stieevo]

Hey, thanks for the answers. I didnt dare to drive the van in the city anymore, but I checked the breather valve.
I dont know if it was completely blocked, but after cleaning it works much better, that I can say.

The pipe comming from the tank to the filter, and from the filter tu the pump looks in good condition, also the fittiongs. Not a sign of any brittle material, loose conection or a drop of diesel.
But from the same hose as the fuel pipe comes to the filter, there goes a pipe to a box wich is situated above the battery. Its all filthy and sure there is something leaking. What is this and could it cause this or another problem?

[twin wheel camper]

That's not standard transit and I've no idea what it is maybe a non return valve

[stieevo]

@ twin wheel camper: yes, I think this could be the non return valve from the tank. One pipe comes from the tank, the other goes into the engine air intake. So it could be that the fumes get sucked in. How was that build originally?
But if this is just a valve to vent the tank, why is there so much dirt and diesel? Could it be, that if the tank is fully filled, and the car is in the sun, and the valve is leaking, that there is acutally diesel comming out and thus attracting the dirt to stick?

Sounds a bit weird, but maybe over many years this could actually happen. Tomorrow I have time, so I propaple will unmount and clean it.

Thanks so far

[bambi mk 1]

Its a reservoir for the cold start plug fitted for cold climates ,doubt its your problem.Have you changed the fuel filter

[stieevo]

@ bambi mk 1: thanks for the info. Googled the reservoir, and this makes sense. Also there is a thermostat plug, so I am pretty sure it was fitted long time ago and its now leaking.

Yes, I did change the fuel filter about 4 monts ago. I had problems to get the engine running after the change, but since that I run it about 5000km and I am confident its installed properly.
Today I will make a test drive, if the cleaned breather solves the problem. I will give an update. Thanks for the help

[gotgcoalman]

Is it a genuine filter or aftermarket one?

I've had issues with non genuine ones a month or so after fitting.

[stieevo]

@ gotgcoalman: its not genuine, its labeld with BSG. Did you have the same symtoms?

[gotgcoalman]

Yes i've had (in the past)

Bad starting/poor running and failure to start shortly after (a month or two) when
using non genuine filters.

They seem a bit hit and miss with the DI.

Some will be fine from 1 change to another and some cause problems shortly after fitting.

[stieevo]

So short update. The cleaning and refitting of the breather for the tank didnt help.
I did a short trip out of the city, all went fine. After a 15min ride I had a loss of power when accelerating, then the engine was starting to starve almost when in idle.
Same as before really, it died-out and I had two restart with break-cleaner twice on a traffic light. Its really a pain, barely made it back to the garage.

Since my problem occurs only after the engine runs for a while or is still hot, I think a negative pressure in the fuel system is still something that makes sense.
Is there a way to check the funtion of the filter, or should I just throw it away and get another (quality) one?

Also are the other thinks I can check? I did google the suggested "Leak off mod". But does that really go with my symtoms?
The engine starts fine- every time, except it did just die-out while running before.

Thanks everyone for helping

[vanfox]

Does your engine have a lift pump? If so have you checked it?

[stieevo]

@vanvox: i dont know, but i did not see one.
I am thinking to loosen the pipe going to the injection and fit a little pump to see if filter is clogged or if I draw air. But I am not sure how much resistance the whole piping and filter should have.