Loss of power and engine shaking (leak off mod already done)

[Hanatarash]

Hi there,

First time poster from the Netherlands. We have a 2000 Mk 5 smiley campervan (Reimo) with the 2.5Di (non turbo) banana engine.

We're having some engine troubles. I've done some browsing on this forum and it looks like the problems we are experiencing are somewhat common in these engines.

While driving the engine will suddenly lose most of its power and start shaking. It won´t go past 80km/h (50mph) after that.
If I've done my research correcty then this probably has to do with air getting into the fuel system. I've checked and one of the previous owners has
already done the leak off mod.

Two questions.

1. The leak off mod has already been done. Could it still be that air is getting into the system or could it be something entirely different?
2. We're off to England and Wales for a month in july and I'm sure we'll encounter the issues along the way. Is there a 'quick fix' I can do when these issues arise? I realize that this is dependent on what the actual underlying problem is, but going on the assumption that it is because of air in the system.

[Hanatarash]

Funny story. As we speak, my wife is stranded with the van after the engine shaking issue reared its head again this morning. She parked it at work and after a few hours tried to start it again. The engine was still shaking and when hitting the throttle van stalls immediately. We haven´t experienced the stalling before.

[Hanatarash]

So it looks like the problem is indeed air. My wife had to call roadside assistance when the van kept stalling. She was told it was air in the fuel system. A bit of full throttling seems to solve this. I can imagine this forces the air out of the system.

I would still like to find the cause of the air leak. What would be the best way to find out where the air is coming into the system?

Thanks!

[MinorMatt]

The quick fix is to carry a 17mm spanner with you - when it starts acting up, with the engine running, quickly undo the union between front injector and its steel supply pipe, then do it up again a second or so later. Diesel will squirt out quite a long way. Thats the highest point and will push any fuel out.

Unfortunately there is no easy way to find an air leak. I would think the most likely place would be the fuel filter housing and would start by nipping up the connectors on the injector pump, making sure all the plastic fuel pipes are fully home and changing the fuel filter. Use a genuine Ford, or bosch filter if you can get one.

If that doesn't help - you can cover the connectors (one by one) in grease to give a bit of a seal - but thats a messy and not particularly reliable diagnostic!

[Hanatarash]

Cheers!

I'll make sure to add a 17mm spanner to the inventory list.

You mentioned 'nipping up the connectors'. What exactly does this mean? Sorry, English isn´t my first language.

[MinorMatt]

Just make sure they are tightened

"Nipping up" is tightening a tiny bit more

[Tolley]

Did you find the problem?

[Hanatarash]

Did you find the problem?

We're off to England for a month next week, so just taking the spanner and hoping for the best.

I'll take her to the local diesel specialist when we return. I'll post here if and when we find the issue.

[MinorMatt]

Just a thought - I've been dealing with a van that had air ingress. It was a faulty fuel filter. Might be worth getting it changed?