Mark6 2.4 Duratorq tddi Fuel faults

[Damnthevan]

I am at my wits end with this van. A couple of months ago I broke down with a fuel fault code and a local garage said it was the fuel pump. Cue me driving a round trip of 280 miles to Merlin diesel in Preston exchanging what I thought was my knackered old pump for a fully reconditioned one and the day after I get it back from said garage it goes again, identical symptoms. Mechanic comes out on a Friday evening and finds the fuel filter loose which wouldn't tighten so a new filter later and I'm back on the road. This time the van has lasted just over a week before cooking out again on my way home from a job. Same symptoms as before, loss of power, engine stalls won't bump or restart and km waiting a 3rd time for the RAC! PLEASE! Does anyone have any idea what this could be? Both times fuel came up on the diagnostic.

[Damnthevan]

After 45 mins waiting for the RAC, in desperation I tried the ignition, held it on and pumped the throttle. It took a few seconds but it ran a little rough then normally. It was enough to get me home but I'm getting fed up going out in it with the thought 'Will I make it home tonight?' Any thoughts?

[Chug]

It sounds like fuel starvation, get a hand primer bulb and remove the fuel line on the filter that comes from the fuel tank, (IIRC its fatter one, front right)connect the hand primer to it and pump it and see if fuel pulls through easily, if not there's a blockage in the fuel line or fuel tank, if it pumps easily then check all around the filter and fuel lines for any sign of bad connections and possible cracks, they are known to crack and let air in under max fuel demand.

[knobby1]

I am at my wits end with this van. A couple of months ago I broke down with a fuel fault code and a local garage said it was the fuel pump. Cue me driving a round trip of 280 miles to Merlin diesel in Preston exchanging what I thought was my knackered old pump for a fully reconditioned one and the day after I get it back from said garage it goes again, identical symptoms. Mechanic comes out on a Friday evening and finds the fuel filter loose which wouldn't tighten so a new filter later and I'm back on the road. This time the van has lasted just over a week before cooking out again on my way home from a job. Same symptoms as before, loss of power, engine stalls won't bump or restart and km waiting a 3rd time for the RAC! PLEASE! Does anyone have any idea what this could be? Both times fuel came up on the diagnostic.

A couple of things..: Never bump or tow start a Transit, especially the Mk6 and RWD Mk7 as they have a nasty habit of jumping cam chain teeth....then your starting issue will be the least of your problems. Pumping the throttle does nothing, they are an electronic pedal and the PCM won't enable the throttle function until idle rpm is achieved.
What were the actual fault codes?? This will give us an idea of what to advise on.
Try it with the fuel cap off, could be a blocked vent line to the tank causing a vacuum, unlikely but possible.

As Chug mentions, you may have an air leak in the low pressure side of the fuel system causing grief, this allows the fuel to siphon back to tank which makes it difficult or near impossible to start, especially a TDDi..

Lord Knobrot

[Damnthevan]

Thanks fellas. I knew it was an electronic pedal as I had to replace it about 5 years ago. I didn't know it wouldn't work to pump it so thanks for that. After spending £1250 at the garage, I think they ought to sort it at no extra charge as now I am doubtful it was the pump at all! I rang them last night and left a voicemail so I'll see what they say. If they refuse I'll find another Garage. Appreciate the input though, and not one to normally tell a professional how to do his job I will pass on the comments. That said he owns a Transit himself so should know what he's doing.

[Damnthevan]

I've spent a small fortune on this in the last 2 years. Timing chain snapped after 4 yrs and 20,000 miles on a reconditioned engine. I was lucky it only spun the cams and didn't damage the head or pistons. Then the alternator & starter motor went. I had about a year trouble free and decided to get it sprayed and added some Minion graphics + £1000 worth of welding. It owed me nothing by then so I figured I'd keep it as Devil you know. January my intercooler went and chucked oil into the water making me think it was a head gasket so this was cheaper. New old stock intercooler £135 on eBay instead of £700. Now this. I am up to about £4500 since August last year and have nothing left.

[Damnthevan]

It sounds like fuel starvation, get a hand primer bulb and remove the fuel line on the filter that comes from the fuel tank, (IIRC its fatter one, front right)connect the hand primer to it and pump it and see if fuel pulls through easily, if not there's a blockage in the fuel line or fuel tank, if it pumps easily then check all around the filter and fuel lines for any sign of bad connections and possible cracks, they are known to crack and let air in under max fuel demand.

Thanks, the mechanic did this when it broke down the day after my £1200 bill. The fuel filter was loose and the fuel had dropped about an inch instead of being full so he changed it for a Ford part as it wouldn't tighten. Been running fine for a week. It did take a while to pump through though.

[Damnthevan]

PS, previous codes said injector misfire which I'm told is very rare and then fuel pump. I haven't had any codes for yesterday as I managed to get it going and drove home.

[knobby1]

PS, previous codes said injector misfire which I'm told is very rare and then fuel pump. I haven't had any codes for yesterday as I managed to get it going and drove home.

We need the actual fault code numbers, like Pxxxx, mechanical injectors don't misfire, they either work or they don't.... and saying it was "fuel" means nothing.

Can you tell us what engine is in it...we know it's a 2.4 but is it a 75, 90, 115, 120 or 125 ..??

Lord Knobrot

[Damnthevan]

It's a 90. RWD 2005 Minibus. LR05HZD

[Damnthevan]

PS, previous codes said injector misfire which I'm told is very rare and then fuel pump. I haven't had any codes for yesterday as I managed to get it going and drove home.

We need the actual fault code numbers, like Pxxxx, mechanical injectors don't misfire, they either work or they don't.... and saying it was "fuel" means nothing.

Can you tell us what engine is in it...we know it's a 2.4 but is it a 75, 90, 115, 120 or 125 ..??

Lord Knobrot

Fault codes are P0149 Fuel Dosing and P1564 Injection Pump ECU. Highly unlikely to be the Injectikn pump ECU but mechanic said it could be an intermittent wiring fault between the pump and engine ECU. He also advised me not to run it on less than half a tank so I've filled up. Last 2 breakdowns were coming down fairly steep hills ?

[knobby1]

PS, previous codes said injector misfire which I'm told is very rare and then fuel pump. I haven't had any codes for yesterday as I managed to get it going and drove home.

We need the actual fault code numbers, like Pxxxx, mechanical injectors don't misfire, they either work or they don't.... and saying it was "fuel" means nothing.

Can you tell us what engine is in it...we know it's a 2.4 but is it a 75, 90, 115, 120 or 125 ..??

Lord Knobrot

Fault codes are P0149 Fuel Dosing and P1564 Injection Pump ECU. Highly unlikely to be the Injectikn pump ECU but mechanic said it could be an intermittent wiring fault between the pump and engine ECU. He also advised me not to run it on less than half a tank so I've filled up. Last 2 breakdowns were coming down fairly steep hills ?

Ok, the 90 TDDi has a VP-30 fuel pump & P0149 & P1564 point to the fuel pump timing solenoid....definitely check the wiring to it before condemning it....but it is a very common issue for the TDDi's. The solenoid can be replaced reasonably easily.

Lord Knobrot

[Damnthevan]

I take it the solenoid is not physically attached to the fuel pump? As the fuel pump reconditioned unit was a 1 piece thing with a new sealed ecu attached, not with wires cut and soldered or crimped.

[knobby1]

I take it the solenoid is not physically attached to the fuel pump? As the fuel pump reconditioned unit was a 1 piece thing with a new sealed ecu attached, not with wires cut and soldered or crimped.

Yes it is... The timing solenoid lives in the back/bottom side of the pump under the injector feed pipes.

Lord Knobrot

[Damnthevan]

Thanks, in that case it is part of the reconditioned unit I purchased from one of the best Diesel pump reconditioning specialists in the UK. I would be astounded if that was faulty. At £702 it wasn't cheap.