Engine cutting out uphill

[Thetaylorbrowns]

Hi All,

This is my first time asking questions on a car forum and I have no mechanical knowledge so bear with me!

We have a 2004 Citroen Relay 2.2 diesel (converted into campervan). We're currently in Italy. One week ago we heard a metallic rattling so took it to a garage and he said it was the crankshaft pulley. This was replaced and everything was fine until we tried to go up a mountain pass and the engine cut out.

This has happened 5 times. The engine light comes on, we loose all power and then it will restart 5 minutes later.

As we'd moved on, we took it to another garage and fully explained the situation (he spoke good English) and he felt there was no way it was linked to the crankshaft pulley. The ECU reading showed "low fuel pressure". He took it on a test drive up the hill and the engine didn't stall but we explained it normally happens after driving uphill for 15-20 minutes, especially when trying to accelerate. He suggested changing the fuel filer. We did that and 1.5 hours later, we broke down again. This time the engine was hot and all fans came on so we got towed down.

The oil level is fine, there are no visible leaks under the van, there are no odd noises, there is no smoke from the exhaust and it drives okay on flat roads.

In your expert opinions, could this be related to the crankshaft pulley fix (possible timing issues)? Or is it just coincidental that two problems arose in one go? Is there anything you would suggest looking at? Just so I have some idea when we take it to yet another garage.

Many thanks in advance,
Sarah

[wheeler]

In your expert opinions, could this be related to the crankshaft pulley fix (possible timing issues)? Or is it just coincidental that two problems arose in one go? Is there anything you would suggest looking at? Just so I have some idea when we take it to yet another garage.

I wouldnt initially think they are related, if any debris got into the timing belt it wouldn't be intermittent like it is, If the fuel filter is good i would probably do a leak off check on the injectors.
When you try to re start it can you hear the fuel pump operating? Its located under the floor in between the front seats.

[PaulC5]

Did the garage give you the fault code that would have been stored when the engine light came on ? A crank shaft sensor can fail when hot but then allow the engine to run again once cooled down.

[Thetaylorbrowns]

Thank you! We didn't get the fault code, he just said low fuel pressure. When it gets to the next garage I can ask for this

[Thetaylorbrowns]

I wouldnt initially think they are related, if any debris got into the timing belt it wouldn't be intermittent like it is, If the fuel filter is good i would probably do a leak off check on the injectors.
When you try to re start it can you hear the fuel pump operating? Its located under the floor in between the front seats.

Thank you! I did wonder if it could be fuel injectors but was hoping is wasn't! We don't have access to the van at the minute to test this but when we started it at the time, we didn't notice anything abnormal! I will add this suggestion to my list

[Thetaylorbrowns]

Update on current situation.
We had the fuel in jectors changed, left the garage and went back up the mountain. There was no power at all, couldn't even get out of 1st gear. It did however fix the stalling uphill.

We went back to the garage and they changed the MAF sensor. They also said the EGR valve was clogged but they haven't changed it so I presume they cleaned it?? (the translation was difficult and they got angry when we tried to clarify). We test drove it again before paying and all seemed fine, but we weren't near any steep hills.

Next day, we tried to go back into the mountains but noticed that there was no pressure so we came back down and decided to leave Italy. We got to the toll booth station at trieste and broke down in the booth. Engine cut out and wouldn't turn over at all. This was a flat road and it stalled whilst we were static. No smoke, no engine/oil lights, no leaks, oil topped up.

We got towed to another garage who suggested the fuel pump. We had that changed and it drove like dream (the best since we've had her). UNTIL we got into Slovenia, doing 80km/h on the motorway and heard an almighty banging coming from the engine. We pulled over immediately. No smoke, no engine/oil lights, no oil leak, oil level still okay. This noise has only happened since the fuel filter was changed.

We're currently waiting on a tow truck again. It's been 5 weeks and we've already spent £3000 - any other ideas as to what this new issue could be?

[GiveMeABreak]

I'd be tempted to say crap in the fuel system - going up the hills (especially with low fuel) may have sloshed all the debris in the tank about and this may have got into the fuel supply lines and be causing some stuttering from blockages.

I would certainly be focussing on the fuel supply area and get some Diesel fuel injection system cleaner into the system to try and sort it out.

I've previously had this spluttering / lack of power on occasion on an older vehicle and more significantly gong up a hill - but got some fuel cleaner in there and went for an Italian tune up to clear it through - a couple of bangs, but carried on and that cleared the problem up.

[Thetaylorbrowns]

I'd be tempted to say crap in the fuel system - going up the hills (especially with low fuel) may have sloshed all the debris in the tank about and this may have got into the fuel supply lines and be causing some stuttering from blockages.

I would certainly be focussing on the fuel supply area and get some Diesel fuel injection system cleaner into the system to try and sort it out.

I've previously had this spluttering / lack of power on occasion on an older vehicle and more significantly gong up a hill - but got some fuel cleaner in there and went for an Italian tune up to clear it through - a couple of bangs, but carried on and that cleared the problem up.

Well this sounds way more optimistic than what we were worrying about! The van was running perfectly after the fuel pump was changed and then suddenly the banging started! Not being mechanics, we pulled in and didn't want to restart it.
Thank you for your reply

[darbuck]

It sounds like what Marc alluded to with dirty diesel. My mother had similar with her car a few years ago. It turned out it was algae growing in the diesel and clogged up the lift pump. I would suggest getting the tank cleaned out to protect new pump and injectors.