Cutting Out, Engine Warning Light Intermittent, Garages Finding No Faults?

[Bexb8818]

Really hoping someone can help.

 

Over the last couple of months our Chrysler Voyager 05 has cut out and lost total power. Some times it will start and run fine again, others it won't for hours. More recently the engine warning light has been intermittently on. I've had the car diagnosed by 2 different garages who used several diagnostic machines between them and can't find any errors - no error codes are given at all. I'm a new driver, since October, and drive my 3 children around daily so I'm extremely concerned and losing my confidence with this car. I'd hate to trade/sell as it's absolutely ideal for us but without the issue being resolved it's very worrying.

 

Has anyone experienced this? Any advice at all would be greatly appreciated.

 

Thanks in advance.

[andyb2000]

Hi there,

Unfortunately this can be a long list of problems, there are lots of posts on here and on other forums and I did a whole video dedicated to it:

https://youtu.be/ucfZfV1cNng

When you say it won't run for hours what does it do, dashboard light up, you hear the starter motor turning the engine over it just never fires? When it does that if you waggle your foot on the accelerator will it catch and start?

Also, the assumption is the cut out is when you do hard acceleration/over 3.5k rpm? That's the common failure. So back to the list:

• Fuel filter - when was it last changed
• Fuel - what fuel do you buy
• Fuel - put a diesel cleaner/additive through it sometimes helps
• If the filter has been changed recently, get the filter assembly checked to make sure its sealed properly, has an o-ring. Worth getting it changed again
• Is it a front or rear fuel filter model? The 05 has different designs, if front check the primer pump and pump it to get it started, if it goes soft it means potentially air/leaking

(Those are just a few that popped into my head as I type, there are lots of posts on the matter!

Engine warning light is a newer one that hasn't been seen in many cases, the fact that the garages plugged in and got no codes means they're not using the right code readers, these need very expensive/special readers
to read the Chrysler codes, so the fact the engine light is on but they see no codes means their reader isn't good enough for the job!

[blackvelvet]

Det the garage to test the oxygen sensors,

[gordy]

Crank sensor doesn't leave a code..

[Alex]

Check grounds/negative wire. Even if think it's good remove clean and refit. Check battery terminals are tight and batteries perfect. How old is battery?Voyager have to have near new batteries or electrics play up throwing all manor of fault codes. Have you had alternator checked?

If all that doesn't solve problems then start fault codes. Find out your ignition key position and turn on off quick three times fault codes will appear in mileage display.

[Bexb8818]

Hi thank you for all the replies.

 

The garage has done a full service and said going by the condition it looks like it's never had one before. We've only had it a few months. They think the service could have solved the issue but they've now found a problem with the cylinders;

 

P0202: injector cylinder 2, overcurrent high side

P0204: injector cylinder 4, overcurrent high side

P0201: injector cylinder 1, overcurrent high side

 

They've told me the service could have solved the issues above as the cylinders were being starved and now they're not so it's a case of driving it and wait and see. If it cuts out again it's a £500 repair so I've everything crossed!! It's driven like a dream since it's service and is starting up without it's juddering noises I was used to so I'm positive - if naively.

 

Thanks again everyone.

[bignev]

Hi Bexb8818, I sincerely hope it's got it sorted for you!

 

See how we all assumed it was a diesel!!!!

 

You are rather close to us, in Cheadle Heath! Ours is LPG though :- )

[Bexb8818]

Nope,it's cut out again this morning has the oil light on and won't start up. Garage are recovering it today. Not been the best buy for us, wish I didn't love it so much!

[bignev]

Hi Bex,

As Andy's list, the very common one is the fuel filter housing cracking, or a slightly iffy O ring seal.

[gordy]

It won't start. Does that mean its turning over but not firing. If it is its a fuel pressure fault. Like bignev says air in system, Injectors leaking too much or pressure bypass on rail...

[Bexb8818]

The engine will eventually start but is showing the oil light and as soon as I put it into drive it all dies and loses total power. The garage recovered it this afternoon and will look at it tomorrow. I really hope it is straightforward. Thanks guys

[andyb2000]

This does sound exactly what I had when mine was at it's worst. At first it just cut out under heavy RPM/load, but when it really failed it did that, cut out basically idling on the driveway.

Also the 'chugging' trying to start was something I've had too, actually mine will still do this when the engine is warm, still haven't gotten to the bottom of that issue but i'm not getting cut outs anymore after working through everything shown.

 

Go through everything in the video, methodically and work through items that you know are 'known good', as pressure relief valve and filter are easily done at home on the driveway so test the easy things before going to the harder/more expensive replacements.

 

Unfortunately NO garage will be able to tell you 100% that one thing will fix it, if they do they're lying as none of these issues generate fault codes in the ECU enough to be sure on the corrective action.

Edited May 2, 2018 by andyb2000

[Bexb8818]

Hi thanks for the reply

The garage found a fault with a cylinder so replaced it, another £300. It's driving ok today although still feels slightly heavy. What's concerning me now is the rpm it goes to 1rpm as soon as I start it up even when I put it into park and am not touching the accelerator. Is this an issue? I am likely panicking over nothing but it doesn't seem right to me.

[SpAwNtoHell]

1rpm? or 1k rpm? if first 100% still something wrong.

 

As for diagnostic: the garage has to have at least a Launch X431 or a Autel MD808 or higher, and having someone that knows at what is looking is a bonus, very rare in my area at least...

[Expoman]

Hi Bex,

As Andy's list, the very common one is the fuel filter housing cracking, or a slightly iffy O ring seal.

The Fuel Filter housing was the issue with mine, every since I replaced it, the car has run perfectly. Garages are drawn to injectors for this symptom set, I had mine replaced and it was nothing to do with them, I solved the problem with research online including this forum, not OBD codes. Good luck.

[scrufgp]

i had same problem with my 2.5crd and 2.8crd 

the 2.5 i replaced all filters (not housings)had tank removed and cleaned no luck sold car in the end 

my 2.8 had exact same issues 

changed all filters fuel filter housing(ie heater/manual fuel pump) still same issue 

sent to diesel specialist diagnosed fuel rail pressure release valve 

cost few hundred quid to diagnose and get sorted but 2 years in now and im still going strong 

my advice is send it to a specialist who knows what they are looking for 

my experiences with 2 voyagers the fuel systems seems to be very temperamental

there are post on this forum about these problems already as well as a big write up on the web somewhere that i read

ps when you get it sorted only use premium diesel cheep diesel seems to worsen your problems   

[scrufgp]

ps listen to gordy and andy 

they a geniuses very very knowledgeable and helped me more than enough times with there advice 

thumbs up fellas  

[bignev]

Hiya @Bexb8188 any progress on your car?

 

Has it - so far - been behaving itself since the last event and fix?

[recepomac]

Check grounds/negative wire. Even if think it's good remove clean and refit. Check battery terminals are tight and batteries perfect. How old is battery?Voyager have to have near new batteries or electrics play up throwing all manor of fault codes. Have you had alternator checked?

If all that doesn't solve problems then start fault codes. Find out your ignition key position and turn on off quick three times fault codes will appear in mileage display.

this friend made a very accurate diagnosis and I got a 2001 model of 2.5 crd and the car dropped and made some strange movements and sometimes smoke from the exhaust was done by the service controls did not find a solution due to enson battery,

[Bexb8818]

Thanks again everybody - such a knowledgeable forum!! The cars been running absolutely fine since the repair and my paranoia has also calmed down ha! So far so good x

[Expoman]

Hi Bex,

As Andy's list, the very common one is the fuel filter housing cracking, or a slightly iffy O ring seal.

 

Replacing the fuel filter housing worked for me. It was cracked and the o ring inside was distorted. Previously, my mechanic had gone down the injector route with no success. Had 000"s of miles of happy motoring after the replacement earlier this year, not a single reoccurrence of the problem.