Hi all starting to run out of ideas with this one.
Ok the quick version of the past 7 months issues with my van.
Back in Jan I noticed a leak from the back of the fuel pump. This turned out to be the usual metering solenoid problem where the sealant breaks down and allows the diesel to leak out. After turning to the forum for advice I bought a new solenoid valve + the special tool for removing it. After having a right chew on replacing it I got the van back on the road with no further problems untill the starter packed up a couple of months later. This I think may have had something to do with the diesel that had dripped from the faulty solenoid into it. Fitted a new starter everything back to normal then noticed another leak. This was eventually traced to a damaged fuel pipe behind the egr valve.
Managed to bodge the pipe to stop the leak and went away to scotland for a weeks holiday. Whilst away we had a lack of power that turned out to be a big split in my intercooler so a new one was fitted. Still suffering with a lack of power mainly when pulling away I replaced the fuel filter after querying the one fitted with forum members as the old one looked like the wrong one.
By now im starting to have problems starting as im having to crank the engine longer than normal. Next up I did an oil change. For some reason I couldn't get the right amount of oil in even though the van was fully drained first. Whilst on the subject of oil there was quite a bit in the intercooler when I changed it. Checked the turbo everything looks fine just looks like its sucking it through the oil breather.
As the starting issue was getting worse I retraced what I had done to the van and decided it must be the fuel pipe that I had bodged so I ordered a new set of pipes. Fitted these a couple of days ago still having issues starting so I started checking for leaks. I noticed a small amount of diesel weeping from the plastic fuel inlet pipe where it pushes onto the new metal pipe so I poped the pipes back off and slipped a couple of o rings onto the metal pipes before refitting the plastic pipes. This pulled the push on conectors on tighter and stopped the leak but still the starting issue was there. After checking the banjo fittings on the pump I relised I forgot to fit the copper washers on so this was done this morning and things started to improve.
We decided to go for a run out up the dales and after stopping for diesel we called in at halfords to pick up a new air filter. Got back in the van after about 15 mins and it wouldn't start. I decided that it must be down to the fuel supply so after buying yet another set of spanners I cracked open the pipes on the injectors to check for diesel. As I had diesel I checked for anything loose and eventually got my brother in law to tow us home.
First I checked the PCM for codes then as none listed I went back to checking the fuel. On removing the diesel filter I noticed it was quite empty so a trip to the garage for a fuel can + diesel followed. Filled up the filter put it back on and then had a right carry on getting the van to start. Once running I carefully cracked the injector pipes to release any air left in the system. This seemed to sort things out and the van seemed to start better but after switching off and leaving for a couple of minutes its back to the endless cranking again. So somewhere I must be getting air in but as to where I have run out of ideas!
One theory I have is it could be something to do with the fuel filter but after wrapping some self amalgamating tape round the top in an attempt to seal it to the filter head there is no change. Should there be a none return valve built into in the filter as the one I fitted is not a genuine ford one?
Forgot to mention the van is a mk6 55 plate 85 280 with the 2.0L di engine. Any ideas anyone?
Cheers Dave.