Throttle position sensor 1995 Mk4 2.5 TD

[digitalimager]

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Hello everyone.
I have an Auto Sleeper Amethyst Motorhome on a Transit Mk4 Platform/Chassis (VE83) 2.5 TD (EME/L/S, ENE/L/S) 74 KW. I've been using it now for nearly three years. Almost immediately I had a problem of little or no response from the accelerator. I had it checked out but no problem could found. Seaqrching online I found a workaround that worked. Switch on, press the accelerator slowly and release quickly, switch off and on and start. A bit of a nuisance but it worked. Until I broke down in Spain earlier this year. The garage checked it out for an hour and a half and could find nothing wrong. No fault. At least they didn't charge me!
So, I thought if no problem I'm not going to bother with that workaround again. Presto. No more problem. I can only assume they fixed the problem unwittingly.
Back home in Blighty, I have just had the van serviced and MOT'd and, bingo, the problem is back with a vengeance. Time to replace the TPS. My problem is I cannot find a replacement anywhere.
Any suggestions would be gratefully received.
Thanks in anticipation.

[MinorMatt]

I have a good used mk4 one on the shelf

[digitalimager]

I have a good used mk4 one on the shelf

Thanks Matt.
As you know, I fitted the TPS from yourself and it ran beautifully on a 20 mile test run.
However, when it came to setting off the next morning, the problem was back! It ran rough and then stalled. I had a couple of mates over to look at it but they were as baffled as me! After fiddling with a few things they managed to get it to run on a fast tick over whilst belching a lot of smoke; white, grey, blue but not black. They left suggesting I take it for a run and the smoke might clear. Needless to say, that did not work. If it runs it's rough and belching smoke. Error codes are 24 and 43 - calibration resistor and advance control.
Unfortunately, I'm no mechanic and am at a loss.
Any help, advice or suggestions gratefully received from anyone.
Thanks
John

[MinorMatt]

On the later pumps the calibration resistor is literally just that - a resistor. Its located in the plug of the pump and the 2 pins are surrounded by white. With a pair of pliers you can pull it out.

The code numbers won't align - but it will be worth having a look at the LDV Lucas EPIC manual (google Ecovippari EPIC) to find it - the code descriptions are likely to be the same.

If it can't see the calibration resistor (section 4.4) - it will barely run, which sounds like the issue you are describing, so I would start there. If you can't find anything wrong a "bodge" fix would be as simple as soldering a resistor across 2 wires where it comes out of the ECU.

Advance control sounds suspiciously like "Cam Position" on the later variants (section 4.3). If this happens constantly you may get lucky and a new sensor will fix it, otherwise its a replacement injection pump. Modern diesel doesn't have the same lubricating properties as period diesel (sulphur) and it is common place to put 500ml - 1L of mineral 2 stroke oil in the diesel (every time) to replace this. If the fault is intermittent adding 2 stroke oil to the diesel has been known to cure it

[MinorMatt]

Oh yes, if you haven't already its well worth checking the pins and sockets in the main pump connector (both sides) for any corrosion, backed of pins or damage....

[digitalimager]

Thanks Matt.
I'll soldier on.

[digitalimager]

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Well, the saga continues.
I've had a mechanic look at it and he has found two loose connections in the multi plug to the pump. They are now completely detached and no way of reattaching them as they do not have the securing plastic sleeves. It's beyond him, apparently, and I need an auto electrician.
I've attached a couple of pictures so you can see what I'm talking about.
Any comments gratefully appreciated.
Thanks
John

[Keef]

Looks like someone's used a hacksaw on the end of your plug?
If the connectors fit through the holes in the plug and you know which pins they connect to you could push them through the plug and connect them up before connecting the rest of the plug maybe

[digitalimager]

Looks like someone's used a hacksaw on the end of your plug?
If the connectors fit through the holes in the plug and you know which pins they connect to you could push them through the plug and connect them up before connecting the rest of the plug maybe

VASELINE!

[digitalimager]

Looks like someone's used a hacksaw on the end of your plug?
If the connectors fit through the holes in the plug and you know which pins they connect to you could push them through the plug and connect them up before connecting the rest of the plug maybe

VASELINE!

What I meant was the plug and socket are smothered in Vaseline
Thanks for your suggestion. We're going to try that although it's awkward because the socket faces towards the bulkhead. So we will snip those two connectors and solder in a longer length of wire to make it easier to make the relevant connections in the socket using a mirror

[MinorMatt]

That could account for it!!

The pins should have little metal tags (probably pushed down now) which lock in to the plastic of the plug to stop them getting pushed back. A plastic "comb" then gets inserted in to the back of the plug as a secondary physical stop to prevent them backing off.

There are 2 options here....

Reconnect the plug with the 2 wires loose and either

Manually insert them in to the appropriate slot and push them home with a small screwdriver, check all is ok and then either find a new comb and replace it or glue them in to place

or

Remove the plastic cover on the pump, cut the corresponding wires inside the pump and solder (or use waterproof connectors) the appropriate wires together...

[digitalimager]

Sorry, just realised I never let you know the outcome of the plug saga.
I made several attempts to reconnect the wires in question but it proved too tricky for me.
I eventually found a mechanic who confirmed the diagnoses and was willing to fix it.He effected a temporary fix which allowed me to drive the 30 miles to his garage [it ran beautifully!] where he fixed it permanently. Job done. Runs perfectly. Better than it ever has.
So I have a spare TPS if anyone needs one.
Thanks again.
Now I need an exhaust system that seems to be discontinued and hard to come by. Or maybe someone can advise if I can fit a later, or similar, system?
Thanks once again.

[Reggie1]

Hi
Just by chance do you still have TPS.
I'm in Australia can't get them here. I have the Lucas 54408439a TPS which throws up codes as reading on ecu inlet pins are show one pin outside of resistance levels.
Wait to here from you
Rodger

[MinorMatt]

Hi
Just by chance do you still have TPS.
I'm in Australia can't get them here. I have the Lucas 54408439a TPS which throws up codes as reading on ecu inlet pins are show one pin outside of resistance levels.
Wait to here from you
Rodger

I may well have a pedal - does yours have 2 square connectors or 1 oval connector?