Please help van cut out now won’t start.

[Goundry]

Right, where do I begin…

My Transit Custom 2.2 started showing signs of the head gasket going, so I booked it in to be done. While it was apart, I had the timing chain changed at the same time. The job was completed and I got the van back.

A few little niggles happened afterwards (boost pipe blew off, etc), which I kind of expected after such a big job. Other than that, it was running fine. I’d had it back about a week and done roughly 200 miles.

I drove from Durham down to Sheffield with my daughter to watch the boxing — van was fine all the way there. On the way back, I noticed a bit of smoke in the mirror from the headlights of cars behind, but the van still drove ok, so I carried on. Then on the motorway it suddenly lost power, cut out completely, and wouldn’t restart. Not ideal with my 10-year-old in the van on the motorway at 1am. RAC recovered us and got us home around 6am.

Current issue:
• Van turns over (cranks) but won’t start.
• Mechanic who did the work checked the timing — says it hasn’t jumped, all still lined up.
• I’m getting fuel at the bleed while cranking.
• He then suspected injectors, so I sent them off to be tested. Result came back that they’re “not great, but wouldn’t stop it from running”.

So at this point I’m at a loss.
Does anyone have advice on what else could cause this after head gasket/timing chain work?
I’ve put the best part of my savings into this van and I’m getting close to just selling it as spares/repair because I need a working van for my job.

[metalworker0]

You'll have to get a scanner plugged into it, read the codes.


all the best.mark

[Goundry]

Cheers for the reply mark! That’s Saturdays mission mate I’ve got the injectors to put back in then I’ll check the codes there was a million codes on it before a sent the injectors off to be tested. I’ll get them back in and put codes up.

[Radiofence]

When u put the key in and turn, are you hearing the 'squidge' of the fuel pump in the tank pushing fuel?

[Goundry]

Yeah I can hear the pump in the tank working.

[Radiofence]

And with it pumping, is fuel coming out of the scrader valve near the big fat air pipe

[Radiofence]

Thinking of things that would stop it outright, the obvious would be fuel (but that seems ok) blocked dpf (could you try creating a gap between turbo and exhaust so something can escape....
Engine oil level ok (not been drank by the engine?).
Compression test ?
Filings in fuel system? (Remove sensor from fat rail and see what comes out onto a dark cloth?
Ill try and think of anything else easy to check whilst you wait.
Definitely get Forscan (free) a Vlinker cable (cheap). And a laptop.
It will help you so much like a long lost father who knows everything.

[Radiofence]

Having problems on the motorway is really scary. I now have a flashing emergency orange light on the roof since I got a flat on the m1 at night.

[Goundry]

Really appreciate you helping me out mate, I’m getting fuel at the bleed. I did check the oil and it looked over filled could a leaking injector put diesel in the oil ? If so would it been too full cause this ?

[Goundry]

I get paranoid about breaking down, especially late at night, so I always carry a few safety bits like amber lights and blankets. Thankfully it wasn’t too bad. Credit to the RAC as well — they sent an independent recovery company out first and took me to Wetherby Services until they could get a unit out to take us home. Because I had my 10-year-old with me, they wanted us off the motorway as soon as possible.

[Radiofence]

That's awsome of them. I use the aa if I need to and they always check stuff like that.

Ive even considered carrying a ground anchor to screw into the ground to tether my boy so he cant move if I was to break down with him in. A truly frightful thought.
Its a good idea to have a 'grab bag' etc.
I have a massive fishing umbrella too. Maybe get some kids ear defenders for her as its very noisey when your put there. And face the traffic always.
If the oil level seems to be increasing, i can only imagine fuel or water getting in - but then ud get mayo/ milk etc

[Goundry]

alright lads tried a few things now


Here’s what I’ve done so far:
• Injectors removed and tested — all fine.
• Replaced the fuel pump pressure regulator (IMV / fuel volume control valve) with a new genuine-spec part.
• Checked fuel supply — it’s getting up to the pump, no leaks.

Even after fitting the new regulator, the van still won’t start and is showing the same fault codes every time:
• P0001 / P0003 – Fuel Volume Regulator “A” Control Circuit Open/Low
• P0113 – Intake Air Temperature Sensor 1 Circuit High
• P02E9 – Intake Air Flow (MAF) Position Sensor Circuit High
• P0670 – Glow Plug Control Module Circuit Open

Live data shows:
• Fuel rail pressure actual: ~20 psi when cranking
• Fuel rail pressure desired: around 4300–4400 psi
• Fuel rail pressure sensor voltage: 0.5 V flat, doesn’t move
• Fuel pressure relief control valve duty: 0%

So basically the ECU is asking for pressure, but it’s not building any.

Because the new valve didn’t change anything and several sensors are showing electrical circuit faults at the same time, I’m starting to suspect it’s not a mechanical fuel issue but an electrical problem — possibly a shared 5 V reference or ground fault somewhere in the loom or around the ECU/battery tray area.

Has anyone had this before or can point me in the right direction? I’ve heard of issues with the loom behind the battery tray or the main engine earth strap near the gearbox, but I’d appreciate any guidance before I start stripping it down.

Thanks in advance for any help — this one’s doing my head in now after having so much work done on it recently!

[metalworker0]

• P0001 / P0003 wiring, you've replaced it .. so it can only be the wiring

the maf and air temperature i believe are one unit .,. this may also be wiring.

i would go through the lot starting with battery terminal and all earths .

GLOWPLUGS will not stop it trying to start - unless you are in minus conditions - some glow plug looms have a week link in the wiring as a fuse, when one glow plug fails it may go to ground blowing this link .. so if you find the link or the fuse blown .. you need to check each glow plug for fault, of going to ground.

all the best.mark

[Goundry]

Thanks for the reply mark mate, do you know where all the earth are by any chance ?

[metalworker0]

Earths - its in the BEMM manual .. you can find it and download for free on the ford uk site, google: bemm manual ford transit custom and it should put you on the correct ford page.

What also you've got to take note of: because the starter is eating electricity current.. readings from other stuff whilst it is cranking is going on, may be false.

and in some cases .. it's the starter consuming so much power that stops it starting. - this would be a faulty starter

You need to take a clip on ammeter to the starter red cable and measure what its using ... should be below 90 amps

all the best.mark