Transit MK4 2.5TD 1994 with Epic DSA947 not starting

[tidroe]

Hello,
i am new to this forum and hope someone can help me with my old 1994 Transit MK4. It has an Epic injection pump DSA947 and does not start after standing for >12 months. The starter is working but the injection pump does not deliver fuel to the (slightly) opened injector inputs. I thought there might be air bubbles in the pump and installed transparent fuel lines but there are only 2 very tiny bubbles (size of a pea) in each line that disappear immediately hwen cranking.

The resistance values of the 3 valves (cam ring, rotor charge, rotor discharge) are 29.9 ohm (measured at the disconnected 35-pin ecu connector).

With help of posts from this forum i could read the error codes with a paperclip and got errors:
12, 24, 14, 16, 33, 55, 54, 22, 23, 61, 43, 62, 41, 35, 45, 11, ... (repeating)

After a reset the ecu showed:
12, 14, 11, ... (repeating)

symptoms are:
- starter is working but no fuel at injectors
- pump does not leak (at least i could not find any leak)
- pump does not make noise
- shut off solenoid is clicking when turning ignition on / off
- calibration resistor has 200k (my manual says it should be between 1k and 68k)
- error code 14

what i tried so far:
- replaced fuel filter
- replaced map sensor
- checked fuel supply to the pump
- cleaned contacts at pump and ecu
- cleaned earth contact near the battery
- tried a different ecu

Does maybe someone have a fault code list for this pump? All manuals that i have found have only the 4-digit codes of the newer models. Or maybe another idea what could be tested next?

Thanks in advance

[MinorMatt]

have you found this?

https://www.google.co.uk/url?sa=t&rct=j ... i=89978449

[MinorMatt]

12 is a code that says "I'm awake" and 11 is a code that says "Thats all the codes read"

Its only code 14 thats of interest - I do have the info *somewhere* but not sure where.

EPIC pumps can be a right sod to bleed up if left dry, but I don't think thats the case with you? As you have a mk4 with the DSA94 - I might be inclined to take the stop solenoid plunger out and see if you get any more luck?

(not all of that link I gave is relevant - but it can be useful)

[MinorMatt]

Code: Select all

For anybody interested, paperclip method is:

- Find 3pin plug in glove box next to the ECU.
- Turn on ignition
- On the side with the ident, bridge the two connectors with a paperclip for at least 5 seconds, then remove
- Watch the engine management light on dash flash (Begin of read is 12, end of read is 11, all codes are 2 digits)
- If you want to clear the codes, once you see 11, rebridge the pins, then turn off ignition. Remove paperclip.

Repeat the above to check codes are cleared, should only have 12 and 11.



Code: Select all

Ford epic Errors 92-94
12 Start Diagnosis
13 Engine Temperature
Sensor 14 Air Temperature Sensor
15 Gas Pedal
Sensor 16 Pump Temperature Sensor

22 Rotor sensor
23 Rotor control
24 Calibration resistor
25 Current el. EGR valve

31 ECU memory
32 Turbine pressure
sensor 33 EGR sensor
34 EGR control
35 ECU

41 Engine speed sensor
42 Low pump speed
43 Advance control
44 Invalid signal from the advance sensor
45 Control unit relay

54 Emergency stop valve
55 Supply voltage

61 Rotor calibration
62 Lead sensor calibration
63 Motor/pump synchronization

51 Pump installation error suspect pump to engine timing,check pump timing.If pump timing is correct,replace pump..
52 Control unit reference voltage
53 Control unit processor
54 =‘reduced power’

64 ADC of the control unit
65 independent memory of the control unit


[MinorMatt]

Air temperature sensor won't stop the van running or bleeding up - so you are looking at a more conventional problem

[MinorMatt]

Air temperature sensor won't stop the van running or bleeding up - so you are looking at a more conventional problem

[tidroe]

thank you very much for the codes! I sent emails to ford, zf and several workshops, but noone had any information about this pumps codes.

It is good to know that the electronic part seems to be ok. In my case code 14 (air temp) came from the removed air filter (including the temp sensor).

Thanks for the hint with removing the shut-off plunger. I will try it in a few days when i have access to the car.

The van was parked ~1 year ago so i assume that the pump was not dry.

Do you maybe know a procedure how to bleed the pump? I tried several battery loads of cranking with opened and closed injector connections and pulled fuel from the tank through the fuelfilter to make sure its filled after the change, but had no success. The pump does not emit a single drop of fuel.

In the frenchcarforum i found a hydraulics plan (not sure if it is for this exact pump):
https://frenchcarforum.co.uk/forum/view ... 28#p676128

Could you maybe have a look at my first attempts to understand how the pump internally works and correct if something is wrong?

The transfer pump pulls fuel from the (external) filter and regulates the pressure to a low level (<1bar ?), that is independent of engine/pump rpm. The fuel gets then delivered to the 3 regulating valves and the shut-off solenoid at the back of the pump. The regulating valves control injection amount and injection time by hydraulically moving the rotor in axial direction or rotating the cam ring. The shutoff-valve enables or disables filling of the rotor. All fuel that entered the rotor gets (heavily) compressed and leaves the pump through the high-pressure lines.

- rotor charge valve
- moves the rotor to the left (decreasing injection amount)
- watched by rotor position sensor

- rotor discharge valve
- moves the rotor to the right (increasing injection amount)
- watched by rotor position sensor (same sensor as above)

- cam position valve
- turns cam ring a few degrees (altering injection time)
- watched by cam sensor

- shut off solenoid
- prevents fuel input to the rotor (no high-pressure output at all)
- unwatched

I wonder if also the rotor position can cut fuel supply completely? If so, could airbubbles (or dirt) prevent the rotor from axially moving without the ecu noticing and paperclipping error-codes?

Thanks for your support

[tidroe]

Over the weekend i could continue looking at the injection pump. Originally wanted to remove the shut-off plunger, but the valve next to it does not look good. My manual says it should be the rotor charge valve, but im not sure if the manual is for this exact pump (it looks very similar). I attached some photos of the shut-off and the other valves.

Currently im stuck removing the block with shut-off and charge-valve because i can not remove the pins/cables from the connector. Does maybe someone know a trick, maybe a clip or hook somewhere? I moved the brown "thing" away and tried pushing and pulling on the pins but they don´t move.

[redline930@gmail.com]

Prob not what you want to hear. But went thru a similar process with my 2.5TD over the last couple of months.
Re-built bits of the epic pump, solenoid o rings etc. But endless faults reported . In the end as many others have done I swapped out the pump for a manual Bosch 460 pump. Still have an engine light on, but it now starts and runs smoothly.

BTW you cant easily remove the pins from the plug in your pic without destroying the plug.
I cut them off and tried some new Deutch Connectors plugs, and did a whole series of diagnostic tests , for continuity and resistance of the various sensors. All were ok and tested ok. But still the faults remained. Much happier now, although the fix wasn't cheap, but cheaper than a replacement campervan!!

[tidroe]

Happy to hear you have your camper running again! I have read through your thread about the conversion. Should i not get the pump running again i will try to swap to a bosch pump too. My transit is a camper too... worked so much on it over the years that its not an option for me to not (let) repair it.

Thanks for the info that the pins can not be removed from the plug. That justified the risk for me of loosing o-rings or springs when working at still connected valves. Finally managed to clean the valves (while connected) without distributing parts to the environment.