1996 Transit 2.5DI Banana engine stopped while driving last week. I'm going to go down a list of all instances in chronological order to encapsulate the problem as succinctly as possible.
1. Engine stopped out while driving. There was the faint smell of plastics/electronics burning. We pulled over.
2. Attempt to restart engine yields no results. Battery has full charge and lights, etc, but no engine turnover.
3. Check all fuses, all ok. Checked starter relay, clicks when it's supposed to, but no engine turnover.
4. Reversed polarity on starter solenoid to attempt to bypass solenoid in case it's faulty, engine turns over but doesn't start.
5. Starter motor begins to whir, but now without engine turnover.
6. We call insurance for a tow to the nearest garage. Garage says they won't touch it because it's been "fiddled with". I assume they mean it's a camper van custom build and therefore they can't be bothered in case something is not as it is in a manual, or something. They do mention the PATS system, but since I'm stuck in France, I don't know exactly what they mean.
7. As they mentioned the PATs system, I assume only a Ford garage can fix it. I bring it to a Ford garage here in France, and the mechanic says he won't touch it because it's a custom build. He also goes on to throw a temper tantrum in French and tells me it will take too much time and money to fix (even though I have enough of both to spare) and starts telling me it's the solenoid, or the fuel pump, or something like that but I can't understand him because he's talking too fast. So, I go back to the van and begin working on it myself.
8. As I can only assume it's the PATs system engaged for some reason, since it turns over when I bridge the starter solenoid connection, I begin the process of bypassing the PATs system.
which involves removing a security cover from the fuel pump stop solenoid. (Pain in the neck)
9. Once that's off, I apply direct current to the solenoid on the fuel pump. Still no turnover and no start.
9. Verify electrical current to both the fuel pump solenoid and starter solenoid using an LED light while the engine is turned on with ignition keys. Both have power. No engine turnover, and of course no start.
At this point I've got only a few ideas:
1. Starter solenoid is actually goosed, and I've goosed the starter engine while trying to reverse the polarity. (But why the plastic smell, and why did the engine stop while driving?)
2. Fuel pump stop solenoid is goosed. Or something. I don't know.
3. There is another solenoid on the fuel pump which has some involvement with the PATs system that I'm not aware of.
I'm absolutely not a mechanic, and all this is probably far beyond my ken, but I'm stuck on the roadside in France, and there is nothing I can do but try one thing after another.
Any help will be appreciated. Additionally, if there are any whiz gearheads in central France right now who can lend a hand, I'll pay.
Thank you for your time.