2010 - mk7 transit knocking and stopping!! help needed pleas

[darkhorse]

ok guys, so I have had the mk7 for about 2 years now, it had a recon engine (with receipt for 3k) with less than 10k on when I bought it but 140k total mileage.

its been fine until the other day.. I haven't been using it much over the past two months as I am now office based, but I started it regularly and did a few local runs. I went to pick up some kitchen units the other day and noticed when the windows were down and I was leaving the supplier that it sounded quite 'knocky'!

I hadnt driven it for a while so thought it was maybe always like that, but as I headed back to the motorway it got worse until I realised I was deep in the sh*t without a paddle. I managed to limp into a supermarket car park, it started getting a bit juddery, and then conked just as I made it to a good place in the car park for recovery!

Many hours later... me and a diesel handy mate tried everything, we noticed a lot of air in the fuel lines, so suspected fuel filter or housing, bypassed the filter diaphragm at the back as instructed by a garage owner we know who does a lot of trannie's, it tried to start but wouldn't, then flat battery,

Its currently dead at a local garage. I went and pulled the fault codes today, there was nothing very meaningful (left position lamp) and on the engine side, PO480 Fan 1 control circuit and PO68A - ECM PCM power relay.
Now I was thinking either thats because the battery went flat or because there was no fuel pressure? has anyone had this before??? hoping my engine isnt trashed!!! (not checked cam carriers yet) Thanks

[darkhorse]

Any ideas guys?

To make my long post above simpler

2010 2.2 tdci started running noisily, it got worse over a 10 mile drive and was knocking quite a lot, I saw ECM light flash, van started to falter a bit and it did on me when I pulled it into a car park..
Since then, we noticed a LOT of air in the fuel lines
Engine is NOT seized, and runs (noisily) and briefly on easy start
We bypassed the fuel filter and I put a fuel pipe into a can of diesel to rule out and air leak on the pipes/filter, it sounded like it tried to start today, kept trying to catch, but wasnt far off. Not sure we got all of the air out even with an inline hand pump.
Fault codes read - they were one for a left position lamp!

and 2 on the ECM side
P0480 Fan 1 control circuit
P068A ECM/PCM power relay de-energized too early


The battery went flat trying to get it running before the codes were pulled, not sure if 68a is from that or fuel pressure.

Could it be the Fuel pump solenoid?? all help gratefully appreciated!

[Punto443]

Injector clamps come loose?

[darkhorse]

thanks, never even knew this issue existed. WIll check and post back

[knobby1]

thanks, never even knew this issue existed. WIll check and post back

Very common on Mk7's, the bolts are quite small considering they need to hold down two injectors each against huge pressures...they're also "single use" and should be replaced each time they're removed.

Not unusual for them to snap, the clamps themselves are also known to break.

Lord Knobrot

[darkhorse]

thanks, never even knew this issue existed. WIll check and post back

Very common on Mk7's, the bolts are quite small considering they need to hold down two injectors each against huge pressures...they're also "single use" and should be replaced each time they're removed.

Not unusual for them to snap, the clamps themselves are also known to break.

Lord Knobrot

many thanks Lord Knobrot

It sounds a pita to have the bolts drilled out if this has happened...? My mates garage is overrun as they had a mechanic leave so the van is still in the bottom yard

[knobby1]

thanks, never even knew this issue existed. WIll check and post back

Very common on Mk7's, the bolts are quite small considering they need to hold down two injectors each against huge pressures...they're also "single use" and should be replaced each time they're removed.

Not unusual for them to snap, the clamps themselves are also known to break.

Lord Knobrot

many thanks Lord Knobrot

It sounds a pita to have the bolts drilled out if this has happened...? My mates garage is overrun as they had a mechanic leave so the van is still in the bottom yard

Just be aware that the loose injector issue is only a "suggestion" of what the issue may be...but it definitely needs to be checked by a competent mechanic.

Lord Knobrot