406 HD1 90 Died on me?

Hi there, & happy new year I'm In desperate need of help, Im a taxi driver and i missed New Years Eve I havn't worked since Xmas. So time is short for me to get it fixed. I am the families sole provider too. History first: Lower end/Gearbox engine staberlise bush has gone soft, when I depress the... show more Hi there, & happy new year
I'm In desperate need of help, Im a taxi driver and i missed New Years Eve I havn't worked since Xmas. So time is short for me to get it fixed. I am the families sole provider too.

History first:
Lower end/Gearbox engine staberlise bush has gone soft, when I depress the clutch the peddle vibrates. The bush is on order.
An intermitant loud ticking noise on the cambelt side of the engine. Havn't pinpointed it yet.
Just replaced the n/s/r anti roll bar link.
I drove fine, giving over 40mpg round town & 60mpg on long runs.

The problem:
Today it was a ***** to get it into 1st & 2nd but ok on others, when stationary & the cluch on the floor the car still juddered forwards.
I pulled off a rourdabout in 3rd and went for 4th but the clutch went to the foor without pressure. I lifted the peddle with my foot and stayed in 3rd for about 1/2 a mile & pulled into a mcdonalds, just as I turned into the carpark the engine died and I coasted to a halt.

I tryed to re-start the engine but it won't start, it turns over, no engine management lights are on, the lift pump under the back seat seems to be working as I removed the fuel pipe on the o/s of the filter housing and got a steady steam of diesel out of the filter.

I took the top half of the cambelt housing off and the belt looks ok to me, I have no idea how to time this up, do you know where I can download/get hold of some decent data so I can fit a new belt/tentioner?

I even pushed what I thought was the cut off switch down a load of times, (Red cappeed thing mounted on the n/s/f inner stut mount) nothing changed.
I took off the battery for a night & charged it, hoping it will reset the ecu and thow up a code. Nothing changed.

Tryed to tow start it in 3rd, but no start. The cluch resumed normal opperation as well?

I have found the the lift pump & relay works fine, I cracked off a pipe on #1 injector and it pumped fuel for 5 seconds, so thats ok.

I measured the battery voltage it read the following

12.80v All off
11.80v 5sec warm up
12.50v After warm up
10.80v On cranking
12.50v All off rising to 12.65v.

Is the battery knackered, would this be the cause of it all?
The starter motor cranks as its always done for the past 2 years (Fast) Is there enough power to turn the engine over but not enough for the injection system?

MY assumption to the problem:
Diesels don't need electricity to run, but to stop the fuel must be stopped, so am I right in thinking that some thing electrical is stopping the fuel getting thru?
What of the noise in the engine bay, could it be a pump dieing/ Bottom pully (So I've read)? Could the pump die suddenly?
Could the engine have shifted and cut into a wire. Why did I loose pressure on the clutch only to regain it again? Are these Items related?
If the belt had jumped a tooth either way, wouldnt I have noticed some sort of ruff running? It was as smooth as normal, a total suprise that the engine cut out.

Last year when I jet washed the engine bay I killed the EGR valve thing which was disconected by Colchester Diesels, he also said that the Air Temp Sender was reading 10% down but he assured me that it was ok.

I am at a loss, I am capable of doing any job myself as I used to own a French garage till I got divorced. I need this car running asap, so if anyone has an idea I'm willing to give it a go.

What I realy need is technical info like Ohms & Volts Data Stuff thats in the dealers/Bosch workshop manual. Has anyone got any that they can let me read or can point me to web pages? Ive been searching the web for 3 days and found some stuff but its not enough.

Its that time of the year when everyone is fully booked or closed and I have no one but myself to sort this out.
So again any help/info as to how I fault find this or even a web page or two would be the best Christmas pressie I get this year.
Thanks to all of you and I hope the new year brings good fortune to you all.

I look forward to your responces.
Yours
Josh.
2 answers 2