Mk7 starts but will not run

[Colin K]

Hello,
I wonder if anyone has any wise words?

I have a mk7 2.4 350 which has done a lot of miles but always ran great. I love her!

A couple of months ago i started her up and she was a bit rough, Got to the top of my road and white looking smoke was pouring out so I turned her around and limped home. When I turned her off that was it she would not start sounded a bit clonky too!
I have just charged up the battery and given her another try prior to getting my tools out. She will start of a fashion if i pump the throttle like crazy but sounds like she is firing on barely two cylinders. Not clonking mind!

Going to start to strip her out tomorrow but I am not sure where to start. First thoughts has the timing belt jumped a cog? Looks easy to take the front cover off. Or could it be the turbo? I have just rebuilt the turbo on my boat but that one is huge compared to the Transit.

Wondered if anyone had any words of wisdom??

Cheers, Colin.

[Airthies]

Get codes read before getting tools out! But have a look round for any blown or popped joints on the intercooler pipes.

[knobby1]

I wonder if the PRV has suddenly let go....!!?? If fuel is pouring out of it's return line during cranking, she's done for. might pay to pop the valve out and check to see if she's in bits....Costs noting to check.

As Airthies says.....get codes read, as blind guessing can get rather expensive.

Lord Knobrot

[Colin K]

Hello both thanks for the replies. Ah now fault codes that is something that I need to learn. Someone has given me a ELM327 mini OBD11 thing. I have downloaded an app so wonder if I can get codes from that? All new to me.

Had a look at the usual pipes and cannot see any splits etc. Started her again and same as before she will just about tick over (if you can call it that). If I pump the throttle like a mad man. No knocking mind which I find sort of reassuring.

I recon have a look at the timing chain and tensioner? Not googled it yet but looks like if I take off the pullys/fan etc then the plate will expose it all. He says hopefully.

Cannot see any diesel or oil leaks anywhere.

One thing that I notice is that the rusty looking lever that is in the turbo/exhaust area is solid I cannot move it. Sure I used to see it moving is that some sort of wastegate?

Thanks again Col.

[knobby1]

Hello both thanks for the replies. Ah now fault codes that is something that I need to learn. Someone has given me a ELM327 mini OBD11 thing. I have downloaded an app so wonder if I can get codes from that? All new to me.

Had a look at the usual pipes and cannot see any splits etc. Started her again and same as before she will just about tick over (if you can call it that). If I pump the throttle like a mad man. No knocking mind which I find sort of reassuring.

I recon have a look at the timing chain and tensioner? Not googled it yet but looks like if I take off the pullys/fan etc then the plate will expose it all. He says hopefully.

Cannot see any diesel or oil leaks anywhere.

One thing that I notice is that the rusty looking lever that is in the turbo/exhaust area is solid I cannot move it. Sure I used to see it moving is that some sort of wastegate?

Thanks again Col.

Unfortunately pumping the throttle will do nowt, she doesn't have a carbie..!! ...it's an electronic "fly-by-wire" jobbie. The PCM will block throttle operation until a stable idle (~800rpm) has been achieved. Not sure about ELM327, never used one...some "generic" readers have trouble reading "all" codes....especially the pending or historic codes which is kept in PCM memory.

Lord Knobrot

[Airthies]

The rod from the cilinder boltrd to the turbo will be fairly stiff to move but if you take of rod from butterfly linkage then the arm should move freely.
Not sure about the ELM327 either but a fair number of folk have been getting a clone version of Ford's VCM and an old laptop for doing any diagnostics.
If you need to go anywhere near a dealer for diagnostics by the time you've walked in and handed over your keys a clone has about paid for itself.

[knobby1]

If you need to go anywhere near a dealer for diagnostics by the time you've walked in and handed over your keys a clone has about paid for itself.

Quite right there Sir.....My whole system cost ~$150 Aussie sheckles....have used it many times on mine and some friends Tranny's..well paid for itself.

Lord Knobrot

[ake]

An elm 327 coupled with Forscan (download for free) will do all the diagnostics you need

[Colin K]

Hello,
Thanks for the messages and thanks for the Forscan link. I have downloaded the demo version onto my android phone I looked it up on my ipad app store and it wanted me to pay about a fiver.
Opening it up it looks pretty good with fault section etc. Tomorrow plug in the ELM 327 and see how we go. Really appreciate the info and will report back. I am coming to the feeling that the timing chain has jumped I am not sure if it can do that in a non terminal way or not but hey ho we will sort it.

Thanks all, Col.

[ake]

Hello,
Thanks for the messages and thanks for the Forscan link. I have downloaded the demo version onto my android phone I looked it up on my ipad app store and it wanted me to pay about a fiver.
Opening it up it looks pretty good with fault section etc. Tomorrow plug in the ELM 327 and see how we go. Really appreciate the info and will report back. I am coming to the feeling that the timing chain has jumped I am not sure if it can do that in a non terminal way or not but hey ho we will sort it.

Thanks all, Col.

Put Forscan on a laptop and its free

[Colin K]

Hello,
I have had a few wee health problems and so not been able to get on with my old van. I am firing on all cylinders again which is more than I can say for the van !!!
Well downloaded FORscan onto my android phone plugged in the ELM327 and hey presto it works got a list of fault codes and its even let me print it off. Wow thanks chaps.
There are lot that just say below limits etc etc but I think my biggie is code PO2AO. Cylinder 2 balance -injector restricted.
I am suspicious that the timing chain has jumped a cog could that show up as this I wonder? AHHHHHHH i just noticed it says damaged or contaminated CKP/CMP sensor

I recon its timing chain cover off I wonder if I am on the right track? Looks like its all at the front of the engine so not a bad job??

Thanks for any advise.

Cheers, Colin.

[Colin K]

Hello,
Stripped her out crankshaft bolts were a pig. Packed up for the day but a quick wiggle shows the chain intact but there is play along the right hand side run so the diesel pump cog wiggles. I wonder if thats right?

I guess next job is to line up all the timing marks.

Cheers, Colin.

[knobby1]

Hello,
Stripped her out crankshaft bolts were a pig. Packed up for the day but a quick wiggle shows the chain intact but there is play along the right hand side run so the diesel pump cog wiggles. I wonder if thats right?

I guess next job is to line up all the timing marks.

Cheers, Colin.

Are you able to post up all the codes? We might be able to sort out a common fault from them. I would have held out doing the cam chain until you know for sure all the other items work correctly. Cam chain will be a bit loose until the engine is running, tensioner needs oil pressure to take up the slack.

Lord Knobrot

[Colin K]

Hello,
Thanks for the reply. Hope its ok to copy and paste the whole document that it gave me.

Cheers, Colin.




PCM DTC P2135:64-28===
Code: P2135 - Throttle/Pedal Position Sensor/Switch A / B Voltage Correlation

Additional Fault Symptom:
- Signal Plausibility Failure

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

Possible causes :

Electrical connectors not fully engaged

Wiring Harness Short to Battery or Short to Ground

Check for continuity shorts to ground and battery positive.

Inspect connectors for signs of damage, water ingress, corrosion, etc.

The CAN communication with the IC.

CAN communication bus fault.


===END PCM===

===PCM DTC U0167:00-28===
Code: U0167 - Lost Communication With VIM

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module
===END PCM===

===PCM DTC P0704:64-28===
Code: P0704 - Clutch Switch Input Circuit

Additional Fault Symptom:
- Signal Plausibility Failure

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module
===END PCM===

===PCM DTC P02A0:00-28===
Code: P02A0 - Cylinder 2 Balance - Injector Restricted

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

If there are any DTCs relating to specific injector or cylinder faults, investigate those first.

Experience has shown that the symptoms of this fault are:

PCL On

Lack of Power

Poor idle

Poor performance

Possible causes :

Damaged or contaminated CKP/CMP sensor and pulse wheel.

external fuel leaks

Low Engine Compression

The ICF does not match the stored values in the PCM.

Run

Service Function

Fuel System Leak Test

Pilot Correction Learn

Cylinder compression check

Do not renew any components until all pinpoints associated with this DTC are complete.


===END PCM===

===PCM DTC P1103:00-E8===
Code: P1103 - MAF Sensor In Range But Higher Than Expected

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC
- Test not complete

Module: Powertrain Control Module
===END PCM===

===PCM DTC P2265:64-2F===
Code: P2265 - Water in Fuel Sensor Circuit Range/Performance

Additional Fault Symptom:
- Signal Plausibility Failure

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

There is a known issue with the PCM calibration on this vehicle.

The issue with the calibration does not affect the normal operation of the vehicle.

This DTC has been set erroneously and should be ignored.

A diagnostic procedure offers a new calibration when it is available.

It may not be possible to clear this DTC.


===END PCM===

===PCM DTC P0089:7A-28===
Code: P0089 - Fuel Pressure Regulator Performance

Additional Fault Symptom:
- Fluid Leak Or Seal Failure

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

If there are any DTC relating to specific IMV faults, investigate those first.

Run

Service Function

Pump Learn

Clear the DTC and repeat the self-test.

If the %(DTC) are still present:

follow the normal diagnostic procedures.

Possible causes :

Air in the fuel system

Electrical connectors not fully engaged

Inspect connectors for signs of damage, water ingress, corrosion, etc.

Short circuit in wiring or component.

Open circuit in wiring or component

Experience has shown that the symptoms of this fault are:

Lack of Power

PCL On

Driveability Concerns

Poor start or no start

Low fuel pressure.

High fuel pressure.

Do not renew any components until all pinpoints associated with this DTC are complete.

Pressure Limiter Operated

pressure limiting valve unserviceable

Fuel pressure sensor


===END PCM===

===PCM DTC P1402:16-AF===
Code: P1402 - EGR valve position sensor / wiring

Additional Fault Symptom:
- Circuit Voltage Below Threshold

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC

Module: Powertrain Control Module
===END PCM===

===PCM DTC P0403:1B-28===
Code: P0403 - EGR Control Circuit

Additional Fault Symptom:
- Circuit Resistance Above Threshold

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module
===END PCM===

===PCM DTC P068A:00-28===
Code: P068A - ECM/PCM Power Relay De-Energized - Too Early

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

This DTC may be caused by :

An intermittent fault.

Damaged or faulty relay

Damaged or contaminated connector

Check the wiring and the appropriate fuse.

There could be a intermittent wiring fault. Check the wiring harness.


===END PCM===

===PCM DTC P062B:16-14===
Code: P062B - Internal Control Module Fuel Injector Control Performance

Additional Fault Symptom:
- Circuit Voltage Below Threshold

Status:
- DTC Maturing - Intermittent at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

Clear fault codes

Drive the vehicle on the road.

Rerun the diagnostic.

Only replace the module if the fault still exists.


===END PCM===

===OBDII DTC P1402-C===
Code: P1402 - EGR system fault.

Status:
- Confirmed - malfunction is confirmed

Module: On Board Diagnostic II

Diagnostic Trouble Code details

EGR system fault.

Follow the routines in the service manual to resolve the DTC listed.


===END OBDII===

===ABS DTC C1A93:14-2B===
Code: C1A93 - Right rear wheel speed sensor

Additional Fault Symptom:
- Circuit Short To Ground Or Open

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Antilock braking system

Diagnostic Trouble Code details

Rear Right Wheel Speed Sensor Circuit

Possible causes are:

Rear right speed sensor open circuit

Rear right speed sensor short circuit

The right rear wheel speed sensor input signal missing or the signal is not plausible.

DO NOT replace the ABS module based on this DTC alone.

Perform these checks

Check the right rear WSS connectors and wiring harness for open and short circuits.

Check that the WSS is properly installed.

Check the condition of all cables and connectors for broken cables, damaged insulation, contamination, water ingress and loose connections.

Check the ABS module connections for damage, water ingress or corrosion . If any contamination is found, clean the connector and ABS module terminals.

Sensor replacement must only be carried out after the following checks are performed.

Check the connector for damage or contamination.

Check for an open circuit in the wiring harness.

The sensor was previously disconnected, check the sensor connector.

Check for a short circuit to the ground or battery.

Check that the supply voltage to the ECU is approximately 12 volts with the ignition in position II.

Disconnect the sensor. Check that the supply voltage at the sensor connector wiring harness is approximately 12 volts, with the ignition in position II.

If there is no voltage the possible fault is the main wiring harness, connector or ECU module.

The WSS Or Encoder Ring Are Damaged

Check that the WSS is not damaged, contaminated or incorrectly installed. Also check for water ingress in the connections.

Check that the air gap between the WSS and tone wheel is not greater than 2.1mm.

The encoder wheel is damaged or contaminated

Check the tone wheel for contamination and damage.

Check the tone wheel is mounted correctly.

Check for even tire sizes and pressures as per the manufacturer's specification.

Check tires and wheels for damage or poor repair.

The tires installed may have different outside diameters.

If a tire mismatch is suspected, swap the tires from front to rear axle and drive the vehicle over 10 mph/15 kph. The ABS lamp remains on until 10 mph/15 kph even when the fault is fixed. If the lamp stays on above 10 mph/15 kph, re-check the DTCs. If a different wheel speed sensor is now faulty, there is a wheel/tire fault issue.

A wheel bearing is worn or loose.

The WSS is checked dynamically while the vehicle is driven at speeds greater than 10 mph/15 kph. If there is a DTC set for the WSS, it is only cleared when the vehicle is driven at a speed greater than 10 mph/15kph. The ABS lamp remains illuminated until the WSS has been checked.

The ABS / TCS lamps will remain illuminated after the DTC has been cleared. They will extinguish after the vehicle has been driven at a speed greater than 10 mph / 15kph.

The ABS module should only be replaced if the above checks have been vehicleried out.

DO NOT CLEAR THE DTCs.

To replace and configure a new ABS module, the following procedure should be followed.

Turn the ignition key to ON (Position II),.and wait for 30 seconds for the lamps to go out. During this time the ABS, EBD, TCS and ESP lamps are illuminated.

Turn the ignition key to OFF (Position 0).

Turn the ignition key to ON (Position II) and check that the ABS, EBD, TCS and ESP lamps are not illuminated after 3 seconds.

After the configuration procedure has been completed, check to make sure the DTC is not set on the new module.


===END ABS===

===ABS DTC U0401:86-2B===
Code: U0401 - Invalid Data Received From ECM/PCM

Additional Fault Symptom:
- Signal Invalid

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Antilock braking system

Diagnostic Trouble Code details

Invalid Data Received From ECM/PCM

The TCS or ESP lamp are illuminated.

There may be DTCs in the PCM.

The ABS module has received invalid data from the PCM.

The PCM is setting the failure bit.

Check the PCM for DTCs.

Do not replace the ABS module based on this DTC alone, unless a fault or physical damage is found.

After the vehicle has been repaired, clear the DTC. Check to make sure it does not occur again after the ignition has been on (position II) for over 30 seconds.

After clearing the DTC, it is not set again if the fault still persists until the ignition is ON (Position II) for at least 30 seconds.


===END ABS===

===BCMii DTC ===
Successful DTC reading, no error codes found

Module: Body Control Module
===END BCMii===

===RCM DTC B1318===
Code: B1318 - Battery voltage Low

Module: Restraint Control Module

Diagnostic Trouble Code details

Battery voltage Low

Possible causes are:

Battery voltage line - open or short

Poor battery condition


===END RCM===

[knobby1]

Wow...that's a lot of wrong going on there

I'd be "Clearing" all faults and try running again to see what comes back...then we might be able to make some sense of them..!

Failing that....it looks more like a load of wiring/connection faults rather than any one particular item...I'd be checking your PCM/module plug connections, relays & fuses etc... and all wiring looms for damage etc...

Lord Knobrot