Hello guys, boy do I need some help here please...

2001 Courier van 1.8 Tdi.

Tuesday night did 20 mile trip with no problems. Weds night and it will not start at all. Glow plug light starts flashing if you crank for any length of time. Did start it 3/4 times out of 30 odd attempts BUT it won't catch.

Fuel filter new two weeks ago
Cracked injectors and fuel getting to them
Cracked banjo inlet to pump and fuel there too

Error code p1664 shows which kind of suggests low fuel pressure and possible air leak in the fuel delivery system?

Any help appreciated as I am tearing my hair out.

Thank you.

 

Pumps are shocking on Fiesta/couriers

used to be the first thing i would sell when one came in for breaking

 

Yes indeed, the Bosch VP44 has a pretty foul reputation. However, I fail to see how it could go just as I am turning the key AND the engine surely wouldn't try to start at all if it was done in?

 

i tend to find when these pumps are on the way out they usually die shortly after having the filter changed as random as it sounds!

 

That would be extremely weird...

 

Let's assume, for the sake of debate, that it is air on the inlet side causing the problem. How and where does one start looking for an air leak in fuel supply lines?

 

not really its usually because instead of using suction or a primer pump to bleed the air out of the fuel people just crank them until they fire which runs the pump dry and is usually enough to finish them off

 

Understood, but I didn't do that. I filled the new filter to the brim and kept the lines full too. It started on the key immediately and behaved impeccably for a fortnight. Then it decided to play dead...

 

P1664 is injection pump control module issue (box on top of the VP44)

you really need to measure fuel pressure and check the CAN network to/from the PCM

 

Could you expand on that second line please Sean?

Thanks.

 

Well, the local guys spent an hour rigging up a diesel supply line to the pump, bypassing the van lines, and it still wouldn't start. The total fault code readout is as below;

p 0409
p 0404
p 0149
p 1664

Are there any sensors on the Endura 1.8 Tdd1 that could cause non start? If so, where are they located.

Thanks.