Bad start and cutting out

[MJ80]

I finally got time to look at this today.
Removed starter and stripped covering off the wiring. Couldn't see or feel any faults. Tested the fuel pump plugs to the PCM plug and tested out fine.
Where should I go next?

[MJ80]

Still going with this one.
When I fill the fuel filter up it will start and run for a couple of seconds but there is no throttle response, then it cuts out and wont restart.
Still getting the P0200 code and it has been joined with P0623

Have fitted new connector to injector loom as that was broken, new leak off pipe kit-Ned I sorted it with a bit of fuel pipe and one of the old connectors

When I take the filter off it is about half full and I seem to have some dripping from the pipes on the left of the filter housing head. Could the problem be here?
I cant see any obvious leaks on the plastic return pipes

Will get another fuel filter and try that

Any other ideas?

[ned]

Get a can of fresh diesel and stick the fuel pipes from the left of the filter in to it (pump side) if the van starts and runs on unfiltered fuel then your issue is filter to tank somewhere.

What do the 2 codes mean (haven't had time to look this morning) N

[MJ80]

Code: P0623 - Generator lamp circuit
Module: Powertrain Control Module
Diagnostic Trouble Code details
Generator lamp circuit
Open Circuit
Short circuit to ground or battery
This DTC may be caused by :
Lamp failed

Code: P0200 - Injector circuit malfunction
Module: Powertrain Control Module
Diagnostic Trouble Code details
Injector circuit malfunction
If there are any DTCs relating to specific injector or cylinder faults, investigate those first.
This DTC may be caused by :
Injector harness
Short circuit
Open circuit.
Improper connection
There is a blockage in the low pressure fuel leak back system.
Injector fault
Perform the Injector Cycle Test if the calibration supports it.
For additional information refer to:
TSB No. 46/2005
Faulty or damaged PCM.

Having said that I have looked at the TSB 46/2005 where it says it is often the ground connection.
P0200 (Shared injector actuation malfunction)
Symptoms:
• Engine cuts out while driving - glow plug warning lamp flashes.
• Engine judders (similar experience to misfiring) - glow plug warning lamp flashes.
Cause:
• Usually faults in the ground supply or the voltage supply to the injectors.
1. Check all ground connections.
2. Often the cause is the ground connection underneath the battery (corroded attachment) (for
Mondeo 2001 (10/2001-) see TSB 44/2002).

I have sprayed some rust loosner on the bolt and will have a go at in this afternoon. Both codes are pointing in that direction, but I don't think it solves the fuel problem. I'll have a go with with the pipes as well see where that takes me as well.

[MJ80]

No change,
Cleaned up the battery earth and tried the pipes in a bottle of fuel.
Had it start a couple of times, but would still die and couldn't get the revs up.
Where next??

[ned]

viewtopic.php?f=5&t=182057&hilit=Ned%27s+no+running&start=105#p1556205

That was my fun

So you have eliminated the filter being at fault so your problem is either the imv on the pump or injectors not opening (neither code points to pump/injector failure) when you say you have checked the wiring did you pull the loom out from the pump and behind/over the starter motor, somewhere in the link above shows how much of the loom I pulled out to find a small break in the wire bloody vans.

With your code reader can you get live data? Does it say whether crank position sensor and can sensor are in sinc. N

[MJ80]

With the pipes in clean fuel it was really behaving the same as with the filter. I have taken the filter off a few times and filled it up and it does the same.
When I checked the wiring to the pump I removed the starter motor and stripped all the covering off back to the point where it junctions off and goes up toward the injectors. I couldn't feel any breaks and I did a continuity test between the plugs and the big pins on plug that goes into the engine fuse box. I couldn't find anything untoward. For the injectors I tested for voltage on either side of the connectors and resistance back to the big plug. Changed the one that was causing trouble - soldered the connection - and it tested out fine. I haven't checked the injector to ground that apparently comes through the bulkhead.
I am using an elm and fortis. What would I be looking for to show the sensor position?

[MJ80]

Had it on charge overnight and the damm thing started and stayed running today. Sounds a bit rough.
These are the codes I got,

p0653 - generator lamp
p0500 - vss circuit fault
p0325 - knock sensor - gave the connector a clean and put it back on
p1608 - This came back after clearing, but not the second time
p0191 - frp sensor range - air needs bleeding out of system?????
p0200
b2550 - dome lamp????
b1318 - low battery

After they had all been cleared I am left with P0200

Somewhere I think there is a wiring gremlin. Anyone able to point me to where to find the ground for the injectors - 53 plate 125 tdci

[v8dave]

the wires go from the ecu to the injectors then return to the ecu.

mk6_tdci_injectors.png

Sorry it's a bit small and hard to read, it's that or get it in pieces.


The earth point for the ecu is usually near it, mk6 is probably on the bulkhead below the main connector to the ecu.

[MJ80]

Got the earth cleaned up by the back pf the PCM and it made no difference.
Took each of the plugs off when it was running to see if it stops. Looks like the problem is with the two in the middle, engine is running on the outer two.
Looking to the injectors as the problem. Haven't got a noid light to test the plug connection. On the injector plug I replaced it is showing a little voltage on the earth side, but when I do a resistance test between the plug and the big loom plug it test it looks OK.
Frustrated

[MJ80]

Just had a message from the injector testing place saying the injectors are full of swarf and they have back back pressure. They have recommended replacing the fuel pump and cleaning out the system.

[ned]

Oh dear are you going to do the work yourself or get the garage to do it.

PF Jones supply new and recon pumps from £400.

Bloody vans. N

[MJ80]

I think I will have to do it myself. Just had a look at what is out there and I cant afford to get a different van over here.
How do I go about cleaning the system out, especially the high pressure rail? I am seriously thinking of replacing everything back to the fuel filter.

[ned]

Don't forget you will need to clean out the fuel tank as well. N

[ned]

Fuel lines are easy to change, not sure how you would clean the fuel rail out.

What are you doing about the injectors? Are you getting them cleaned or replacing them. N