P1631

[erikdcc]

Hello everybody, I have a 03 transit 350 90PS, was driving along all over sudden the van cut out, and would not start again, got it towed home, scanner reading was P1631 Main relay problem, changed all the relays underneath the Bonnard but no joy, the van just will not start, starter motor is turning over no problem, I was wondering if anyone can help?

Best regards Eric

[TIMO]

This may help mate .
viewtopic.php?f=5&t=57398&p=495080&hilit=P1631#p495080

[DiscoDan]

Sorry to bring up an old thread but I've pretty much got the same problem, same van, just randomly cut out on the motorway whilst I was away in France, got it brought back home and I just get the P1631 code, if I clear it then try to start it again, the code reappears.

I've posted a quick video of what it does when I try to start it: http://vid193.photobucket.com/albums/z20/discodaniel11/Mobile%20Uploads/IMG_7016.mp4

So far I have had a quick nosey over some of the wiring.
Swapped a few relays around to test.
Cleaned up my battery connections.
Also put on a spare starter I had - Checked the voltage to the starter an that's fine.

Does anyone have any advice? Thanks in advance

[paul2012]

Sorry to bring up an old thread but I've pretty much got the same problem, same van, just randomly cut out on the motorway whilst I was away in France, got it brought back home and I just get the P1631 code, if I clear it then try to start it again, the code reappears.

I've posted a quick video of what it does when I try to start it: http://vid193.photobucket.com/albums/z20/discodaniel11/Mobile%20Uploads/IMG_7016.mp4

So far I have had a quick nosey over some of the wiring.
Swapped a few relays around to test.
Cleaned up my battery connections.
Also put on a spare starter I had - Checked the voltage to the starter an that's fine.

Does anyone have any advice? Thanks in advance

Too possibilities...

1. Battery Useless - May have volts but not enough cranking amps.
2. Lazy starter motor.

I would replace battery first.

[DiscoDan]

Too possibilities...

1. Battery Useless - May have volts but not enough cranking amps.
2. Lazy starter motor.

I would replace battery first.

Thanks Paul, I'll swap the battery today for a known good one an report back. Glad their inside on these, obviously out comes the rain when work needs doing!

[ake]

That code will always appear if the battery is low, or after repeated cranking attempts

It's almost never the relay at fault!

[DiscoDan]

Okay so I swapped out the old battery and it defiantly feels/sounds much stronger now, but still won't start.

I cleared the code an none have returned.

Made a quick clip of what it now does: http://vid193.photobucket.com/albums/z20/discodaniel11/Mobile%20Uploads/IMG_7049.mp4

It's like it wants to do it but somethings stuck, you can feel through the gear stick. I defiantly know the other starter I put on works.
I usually start it clutch down, not making any difference to this situation though.

I was doing around 67mph when it just randomly cut out, I didn't hear anything out of the ordinary :/

Thanks for the help

[paul2012]

Providing it's got a good battery.

1. Lazy Starter motor - May work ok on the bench. When fitted, don't have the strength to crank engine over.
2. Check GND strap from battery to floor.
3. Check GND strap front N/S chassis to Engine.

If all of the above is ok.

4. Get a socket on crank pulley & see if you can rotate crank by hand - This will rule out a seized engine.

[loot]

I'd check that the engine rotates next, something is killing the power

[DiscoDan]

Ok cheers guys.

I Just popped out to try rotate crank, couldn't fit with my breaker bar or wrench though as the viscous fan was in the way, guess my socket is too long

So just had a quick go with the spanner, not much leverage I know so wasn't able to turn it clockwise, was able to go anti-clockwise a little though (not sure if that's ok to do or not), before the bolts then obviously started to unscrew.

Tried to start it an it seemed to spin then get stuck at the same point where it originally was again an would go no further, did this twice with the same result, the second time I recorded it, hopefully I haven't made things worse

Here's what happens, recorded it from underneath this time: http://vid193.photobucket.com/albums/z20/discodaniel11/Mobile%20Uploads/IMG_7060.mp4

Do you think I'll have to take the cover off? Or should I try turning it clockwise properly before that?

[loot]

It's looking a bit stuck when the engine died did it getting to a sudden halt or rotate to a stop? Can you try backing off further then rotate tool it locks? Just trying to confirm that something is catching.
You don't really want to force it tho tbh, is it possible that the timing chain has snapped or something like that.
You may have also snapped a con rod but they usually pop out of the block to say hello.

Fingers crossed it is the starter but it is engaging and turning a bit, it just seems that there is a stop on the engine tho

If you put your bar on 1 bolt and another socket on another nut, you may be able to have the 1 leaning on the other to rotate the pulley without undoing the bolt. failing that, put 2 sockets on 2 bolts and a bar between them and lever round to rotate.

[DiscoDan]

Indeed it is I'd say more of a rotate to a stop, only because there wasn't any sudden jolt or anything. Just some vibration as I was rolling along briefly still in 5th which stopped when I quickly depressed the clutch an back to neutral.

Yeah I'll have another crack at it tomorrow in the light perhaps, I think I get what you mean in regards to the pulley, makes sense in theory anyways shall let you know how it goes. No signs yet of an uninvited rod popping out to see the world hopefully it stays that way haha

Only did the chain, revised tensioner etc just over a year ago, genuine too

[loot]

Yes I'd be interested to know how you get on

Obviously at this stage it could be anything Lol but if the engine is locking up then that needs investigating.

[DiscoDan]

Felt nice an energetic today so whipped the front off, much better access! along with the timing cover (needs doing anyway as its leaking in places).



Now from this position, say 1 o'clock (referencing the bolt on the crank) I rotate it clockwise almost fully...



...But then it stops at around 11 o'clock and will go not further...



and vice-versa, it won't complete a full rotation

[loot]

You need to take the rocker cover off and watch the valves moving when you rotate, with the injectors out it should be easier to turn, you may get a long thin bar or something and put it down the injector holes 1 at a time to see if the pistons are moving as they should.
I've not done all that on my van so the info is based on an older petrol engine but hopefully the same applies.

I'm thinking a broker con rod and it is catching somewhere but i hope I'm wrong