2.0 MK6 SUDDEN CUT OUT PROBLEM?

[PepperRed]

Hi there been a member for a bit now and just been a bit of a background member really reading posts and using the info to sort little repairs here and there.

this is quite long winded bear with me if i explain everything in detail i may help others aand hopefully help my ongoing saga. Just useing this opportunity to say HI TO ALL and to start off my journey explaining a fault that has arisen with the running of my Transit 100 t280 2.0 TDCI.

on 03/12/2015 on a trip to shefield we took the shortcut from the M62 through to the M1 it was on this road i came up behind a car that was turning i realised late and breaked hard and selected 2nd to set off again after the car turning.It was at this point the van smoked and with a plume of blue smoke cut out and managed to coast into a sidestreet.

from this point on the van refused to start and after many atempts the van showed a small glimmer and started then run at about 300rpm i attemped to give the van more throttle but the accelerator was none responsive and the van cut out.

i dont have breakdown so i had to get onto the internet fast either find a solution to get us home or to get the van looked at the latter prevailed as a local mechanic called a friend of his who was a local diesel specialist only a coulple of miles away which was funny! i had to decide wether to go with the diesel guy or to get a recovery the diesel specialist said it would be a tow and diagnostic for £60 so i agreed and off we went to the specialist.

J Wright and Sons in Wakefeild WF4 4DX was the company
Got me straight there got us both a cuppa and they proceded to put the van on the Bosch diagnostic. This investigation showed that there was a fault with the fuel pump but the mechanic said when this was reset the code went away and has not shown again after. he explained that when the pump was "starved of fuel " for any reason the pump will show this fault.

they took the fuel line fron the tank and put it onto a separate fuel supply in the engine bay then they released an injector and they said there was sufficiant pressure at the injectors which could rule out a fauly pump? he then took the van for a test drive in the local area and he returned and said that there was no problem with the performance or anything he was actually quie smitten with how clean the van is and how the engine sounded. i went with him again on another test drive same again no faults the boss of the garage said to whip the fuel filter off the van which he did but dropped it into the parts washer without inspecting the quality of the diesel and or if there were any "suspicious" particles in the fuel
he fitted a new filter MAHLE KC233

And that was that we was on our way home the van on a couple of occaisons felt as if it was a little underpowered but we stuck to the A-roads just in case it happened again but lucikly it didn't

** from this date the van has run fine up until........

2nd breakdown 5/01/2016 was a very similar scenario breaking for vehicle that just pulled out on me going from 40 to 15mph instantly and agin it happened the van stalled, no engine warning lights just conked out this time it took ages to start on a couple of occasions it started then cut out similar to the first i then removed the fuel filter then i took off the diesel tank cap ? dont ask why i jusrt thought it would help the situation. I tried to start then it started and has run fine since.

3rd Breakdown 29/01/2016
this time simila scenario coming up to temp traffic lights van cuts out smokes and coasts into parking spot same again lots of turing over of the ignition for about 15 mins then it started run at low RPM then cut out more tries and then it started kept it on full throttle with the clutch in 3000rpm max? it has like a rev limiter? set off again thinking it was fine. attemped to go up a steep hill in the town where i live ( this was 2 mins after getting going again and got to the top allow traffic and the van died this time there was no starting it 15 mins of cranking flattened the battery and put a pungent burning smell into the cab/under bonnet area and a little smoke under the bonnet (think this could be the starter heating up)

the reason i am here is after recovery i want to get to the bottom of this fault and i will be doing it myself and hoefully with help from you guys and therefor we can learn and help others i need eliminate what is going wrong and

I am looking to buy a diagnostic system can anyone tell wether the DELPHI DS150E would be an apprpriate tool for the job i have an old laptop and i am fimilliar with windows platform for installing etc so no help needed there i am just looking to get something that if i do need to buy parts that need coding ie Injectors can i do this with this software?
Back to the van it has recently had a EGR delete, oli change and filter. One thing i have done recently that i am thinking may have contributed to my woes is i have give the van a dose of Millers additive but think too much for the ammount of fuel in the van. Could i be right in thinking that the millers has loosened off dirt buildup in the tank and everytime i brake suddenly o the dirt shifts and clogs something in the tank starving the van of fuel? just an idea it just seems too be a fuel starvation in my book anyone with expirence with millers?

so if you have got this far thanks for listening / reading the van is on the drive and i will be ready when the hanes arrives (just ordered on ebay) whe would you reccomend i start? The battery is on charge ready.

Hope i can get to the bottom of this thanks Alan

[mickeymouse85]

1st off get a genuine ford fuel filter and by the sounds of things it mite be a crank sensor but that's just a guess mate Hayes manual are shite 2nd you need it on ids to find out the mk6 are a fusy beast

[ake]

Needs fault codes read.
They won't rev past 3000 with clutch in
Could be fuel lines from tank choking up
What is temp gauge doing when problem happens? Could be faulty cht

[PepperRed]

Thanks for the replies, I have been looking into ford IDS but unsure what to buy there are cables that are £12 and setups that are £1k and up

can anyone explain in detail what system they use, where to buy from and will a cheap cable and a laptop based system do the same job as a expensive setup?

Or maybe give me a link to a previous post

[knobby1]

Or maybe give me a link to a previous post

Try this:

viewtopic.php?f=5&t=155150&hilit=IDS+for+idiots

Lord Knobrot

[PepperRed]

Great stuff I better get reading lol 40 odd pages!!!

Thanks

[PepperRed]

Decided to buy VCM2 from http://www.cardiag.co.uk

€119 and 3-5 days with DHL postage (it didn't mention anywhere that they are on holiday till the 14th of Feb so beware if you need it fast like me

Got a little further today, the tank was dropped found a torn breather pipe, and the pick up removed everything looks brand new bright white so I'm guessing this isn't at fault

although the fuel looked quite blue is this normal? I did see a few little shards of metal in the bottom when I shine the torch into the bottom of the tank

[PepperRed]

Ah no joy as yet expecting the scanner today at some point

If you are thinking of purchasing this scanner just take note as DHL are now pulling parcels and checking them, the company the VCM was purchased through (cardiag.co.uk) puts on the invoice that the parcel is worth $37 but DHL sent an email saying it's an undervalued parcel and are asking me for a copy of the original purchase receipt before they release the parcel

Not had many takers or comments from this site so had to find info elsewhere. I know you can't help without faul codes this is understood anyway I found this topic on RAC website of a very similar scenario just to help others

http://www.rac.co.uk/forum/showthread.p ... e!!!/page1

[paul2012]

Hi there been a member for a bit now and just been a bit of a background member really reading posts and using the info to sort little repairs here and there.

this is quite long winded bear with me if i explain everything in detail i may help others aand hopefully help my ongoing saga. Just useing this opportunity to say HI TO ALL and to start off my journey explaining a fault that has arisen with the running of my Transit 100 t280 2.0 TDCI.

on 03/12/2015 on a trip to shefield we took the shortcut from the M62 through to the M1 it was on this road i came up behind a car that was turning i realised late and breaked hard and selected 2nd to set off again after the car turning.It was at this point the van smoked and with a plume of blue smoke cut out and managed to coast into a sidestreet.

from this point on the van refused to start and after many atempts the van showed a small glimmer and started then run at about 300rpm i attemped to give the van more throttle but the accelerator was none responsive and the van cut out.

i dont have breakdown so i had to get onto the internet fast either find a solution to get us home or to get the van looked at the latter prevailed as a local mechanic called a friend of his who was a local diesel specialist only a coulple of miles away which was funny! i had to decide wether to go with the diesel guy or to get a recovery the diesel specialist said it would be a tow and diagnostic for £60 so i agreed and off we went to the specialist.

J Wright and Sons in Wakefeild WF4 4DX was the company
Got me straight there got us both a cuppa and they proceded to put the van on the Bosch diagnostic. This investigation showed that there was a fault with the fuel pump but the mechanic said when this was reset the code went away and has not shown again after. he explained that when the pump was "starved of fuel " for any reason the pump will show this fault.

they took the fuel line fron the tank and put it onto a separate fuel supply in the engine bay then they released an injector and they said there was sufficiant pressure at the injectors which could rule out a fauly pump? he then took the van for a test drive in the local area and he returned and said that there was no problem with the performance or anything he was actually quie smitten with how clean the van is and how the engine sounded. i went with him again on another test drive same again no faults the boss of the garage said to whip the fuel filter off the van which he did but dropped it into the parts washer without inspecting the quality of the diesel and or if there were any "suspicious" particles in the fuel
he fitted a new filter MAHLE KC233

And that was that we was on our way home the van on a couple of occaisons felt as if it was a little underpowered but we stuck to the A-roads just in case it happened again but lucikly it didn't

** from this date the van has run fine up until........

2nd breakdown 5/01/2016 was a very similar scenario breaking for vehicle that just pulled out on me going from 40 to 15mph instantly and agin it happened the van stalled, no engine warning lights just conked out this time it took ages to start on a couple of occasions it started then cut out similar to the first i then removed the fuel filter then i took off the diesel tank cap ? dont ask why i jusrt thought it would help the situation. I tried to start then it started and has run fine since.

3rd Breakdown 29/01/2016
this time simila scenario coming up to temp traffic lights van cuts out smokes and coasts into parking spot same again lots of turing over of the ignition for about 15 mins then it started run at low RPM then cut out more tries and then it started kept it on full throttle with the clutch in 3000rpm max? it has like a rev limiter? set off again thinking it was fine. attemped to go up a steep hill in the town where i live ( this was 2 mins after getting going again and got to the top allow traffic and the van died this time there was no starting it 15 mins of cranking flattened the battery and put a pungent burning smell into the cab/under bonnet area and a little smoke under the bonnet (think this could be the starter heating up)

the reason i am here is after recovery i want to get to the bottom of this fault and i will be doing it myself and hoefully with help from you guys and therefor we can learn and help others i need eliminate what is going wrong and

I am looking to buy a diagnostic system can anyone tell wether the DELPHI DS150E would be an apprpriate tool for the job i have an old laptop and i am fimilliar with windows platform for installing etc so no help needed there i am just looking to get something that if i do need to buy parts that need coding ie Injectors can i do this with this software?
Back to the van it has recently had a EGR delete, oli change and filter. One thing i have done recently that i am thinking may have contributed to my woes is i have give the van a dose of Millers additive but think too much for the ammount of fuel in the van. Could i be right in thinking that the millers has loosened off dirt buildup in the tank and everytime i brake suddenly o the dirt shifts and clogs something in the tank starving the van of fuel? just an idea it just seems too be a fuel starvation in my book anyone with expirence with millers?

so if you have got this far thanks for listening / reading the van is on the drive and i will be ready when the hanes arrives (just ordered on ebay) whe would you reccomend i start? The battery is on charge ready.

Hope i can get to the bottom of this thanks Alan

Transit 100 t280 2.0 TDCI.

It will be a Transit 100 t280 2.0 TDDI.

[PepperRed]

Yea that one

[PepperRed]

OK its been a while since my last post, just an update really from where i left off

I received the the VCM II after all the customs mithering, asking me for proof of purchase ? don't know what happened there. Ive got it now so not bothered

I have spent the last week solid, with the Laptop trying to get it to run the IDS stable firstly tried it on Win 7 Ultimate worked up until the first update learn? then ceased to work so went to try the virtualware machine route - (it comes loaded on the IDS disk that came with the VCM) basically it mounts a virtual copy of windows within your existing operating system. Also on the same disk came a copy of windows xp pro sp3 to load up into the virtualware machine tried this and worked. after a while it ran into memory problems and the prog started stuttering fed uo with the continuous failings i decided to do a fresh install of XP sp3 and loaded everything up. everything went smoothly and everything loaded up fine VCM connects etc

SO today i plugged the van in not really knowing what i was doing just following the on screen commands i find it is pretty foolproof and user platform is quite easy to use (its just back and forward ok and quit )

finally found the CMDTCs function and run a test it came up with 3 faults

1. (B1202) HYBRID ELECTRONIC CLUSTER (HEC):-
Description
fuel sender open circuit
possible causes
suspect fuel sender;fuel sender wiring open circuit

2. (B1359) HYBRID ELECTRONIC CLUSTER (HEC)
Description
Ignition run / accessory circuit failiure

3. (P1631) POWERTRAIN CONTROL MODULE (PCM)
Description
PCM main relay open circuit
short circuit to ground or battery
This DTC may be caused by loose/
poor battery connections at the batteryand engine block
power relay.


Reset the codes the top two had gone but still left a PCM fault, but this time was showing as
No response on Bus + and Bus -
Possible causes;-
Module not responding. This module may be optional. check to ensure vehicle is equipped.?
No power to the module
no ground to the module
module is faulty

ok after resetting this code i was left with no codes?

(apart from the optional equipment modules 8 of that all had fails)

can anyone throw any light on what the vans issues could be? ive left it for this evening its too cold plus without any prior knowledge of what to check there isnt any point of me continuing today as i am going to have a good root round on the internet see what comes up on these issues

thanks

just thinking i would be best making a start buy refitting the tank and getting it primed up and going from there anyone any good methods of re priming the fuel system? what would i need?

[ned]

Sounds like a broken wire to the fuel pump or relays, now you have cleared the codes try starting the van and see if any code come back up. Might narrow down where to start looking.

[PepperRed]

Ok I have been out to the van replaced the fuel in the filter up to the top with fuel tapped it so all bubbles are eliminated
i have disconnected the return line to the tank (left hand side rear tube(small)) is this correct ? of the filter housing i have then put the return feed into a empty 2L water bottle and then turned the engine over then repeated the process about 8 times fill -turn fill-Turn etc to be honest there is about a cup of diesel in the bottle is this right

Could anyone reccomend a alternative way of bleeding the system? or is what i am doing correct?

Van has enough power in the battery no warning lights coil light out and alarm lamp out all normal ????????

[PepperRed]

Anyone?

[PepperRed]

Ok been out again spent the day filling the filter reconnected the fuel lines to the housing put on a fully recharged battery as i flattened it yesterday tring to get it to start

you will have to bear with me as I playing it by ear as i have had no replies to direct me

pulled off the inlet tube from the air filter to the inlet manifold sprayed GT85 (bike lubricant) directly into the tube while cranking engine it was turning for about 45 seconds then i heard a splutter then 1min in it fired got to rev and it died. I repeated the process with the gt85 and it then fired and started to run - i am presuming the airlock had cleared itself and normal running resumed.

it was at this point i grabbed the laptop and read the DTC codes there were new codes that i hadnt seen before

P0149
P1563
P1664
P0500

anyhow the most important code (i think was the P0149) as it mentioned in the description for one of the causes for the fault was "Air in the fuel system"

to me this will explain the way the van cuts out its as though it draws air then splutters to a stop and wont start until the airlock ? is removed' all making sense now. i reset the codes and all codes have cleared. i turned the van off and it is very sketchy to start but does start and runs well

Going back and double checking over the fuel lines i have been inspecting all of the unions where the lines meet the various couplings ie the filter housing and i can see that a couple are leaking i did think about replacing the whole line set but i have noticed that replacing them wouldn't be beneficial

would anyone know where a O-Ring set could be bought to replace the existing ones? or could the unions be bought separtely?
i thought that i would start to chase this problem down this would be a good place to start

if it is just the pipes i have to buy is there any part numbers for the whole set?

i have noticed lots of fuel filter housing problems on here my model is the version with the 90 deg indicator on the front is this one susceptible to failiure?

i know there are so may questions i have but i want this thread to be informative for others with this fault or similar symptoms

Can anyone think there is anything i have missed or overlooked? that this could be?