2.5Di Won’t Start

[Fletch27011968]

There is an ignition relay bottom left of fusebox labelled with a roman 1 here https://www.autogenius.info/ford-transi ... x-diagram/
and I think you said you have already checked immobiliser fuses 32 and 33 ?

I assume being non turbo it has the bosch VE injection pump? if so look at the back of the pump just above where the injector pipes exit from the square iron section and find the wire going to the fuel stop solenoid(part no 240 here) https://dieselcatalog.online/en/bosch/0 ... 14119.html (Hover mouse over to zoom in the picture)

and check that there is a +12v feed to the wire there with the ignition turned on, if there is power there then touch the connector on and off the solenoid spade terminal and listen closely and you should hear the solenoid clicking as it engages and disengages.
With +12v to the solenoid and the same to the starter solenoid it should turn over and start if the rest of the fuel system and engine are in good working order, which it sounds they are because it runs on easy start.

Replaced all spade fuses, have not replaced the ignition relay as cannot source one with it being Boxing day but will have a look on ebay and replace this for elimination.

The link for the diagram isn't working from my end. It does have a Bosch pump, I can see there is 3 wires coming from the back of the pump going to a connector. I cannot see which wire goes to the fuel stop solenoid, do you know which colour it is?

Not get any voltage to any of the 3 wires at the connector when the ignition is turned on. Also not getting any power to the connector pictured below, the wire goes to the solenoid.

transit pic.jpg

[Fletch27011968]

Check, replace or bypass the relay on the bulkhead behind passenger side dash.
You pull out the cubby in the top of the dash above the glovebox to access it.

What am I looking for to check this?? It seems very hard too access after taking the top section off.

[Chug]

There should be three wires going under the cover to the pump stop solenoid, IIRC it's a red/white wire that is 12v+. I think the others are brown and a black/purple.

The starter relay under the cubby hole is yellow, just unplug the relay and use a small piece of wire with 2 spade terminals to bridge, or look up under the dash from the passenger footwell if you cannot see the relay from the cubby hole at the top.

[Fletch27011968]

Thanks for this found the yellow and ignition one - I’ll replace both of these (I’ll do one at a time, So I can get refund on one that is OK) - I’ll try shorting out the yellow first presumably - One running across and the vertical below it - (1 runs crossways 3 run vertical - No1 and No2 Below). If this doesn’t work I’ll replace anyway

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Thanks for this when I tested this I had no voltage to any of the 3 wires.

[frankieboy231]

You say a 'hot wire' turns the engine. I take it that when you try the key - nothing happens but everything checks out.

Had this a couple of years ago and turned out to be red cable from battery to starter (original Ford fitted) was not passing sufficient current to solenoid (probably cracked inside) but good-pull on cable when somebody else turned the key made the connection and started ok. Ended up replacing cable with heavy-weight jump-start cable and looked good ever since.

[frankieboy231]

Sorry posted to wrong caller - dunno how --ignore my previous

[Fletch27011968]

You say a 'hot wire' turns the engine. I take it that when you try the key - nothing happens but everything checks out.

Had this a couple of years ago and turned out to be red cable from battery to starter (original Ford fitted) was not passing sufficient current to solenoid (probably cracked inside) but good-pull on cable when somebody else turned the key made the connection and started ok. Ended up replacing cable with heavy-weight jump-start cable and looked good ever since.

Thanks for reply Frankie. Hot wire probably wrong term, but I mean when placing wire from positive on battery to the positive on starter. The engine then turned but didn’t turn fully over into life.

Will have a look at this wire. To be honest who ever has had the van before looks like they’ve made a bodge of some of the wiring so really need to strip it all back and start from scratch but haven’t got round to it, which I what has probably caused this problem. Luckily it’s only my camper for use in summer and not a daily so not in a massive rush to get it sorted.


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[Fletch27011968]

I have changed all the solenoids check all the fuses - now stripped back of fuel pump to bypass PATS - I have a live supply from the fuse box No.34 (air bag one) to the pump solenoid, now What do I need to do to starter motor, do I just take a feed from ignition to the low tension feed on starter motor? Thanks.

[Keef]

If it still doesn't spin over after everything you've done I'd suspect either the ignition switch itself or the wiring between it and the starter.

s-l640.jpg

[Chug]

If you have power to the solenoid now then you need power from ignition switch when in the cranking position to the small terminal on the starter motor.

[Fletch27011968]

Thanks for all the advice now sorted, bypassed PATS bypassed fuel pump and starter circuit all good.

[Chug]

Well done

[Fletch27011968]

Thanks all the help very much appreciated.