Spares or Repair

Hi All,

There are other threads on here from me with regards the problems we've had with our 1999 Pug Boxer Symphony. We've given up trying to fix the problem and the van is now up for grabs, spares or repairs.

It's been with someone the last six months with no luck finding the root cause of the shuddering problem under load.

Here's my previous threads [You must be registered and logged in to see this link.] and [You must be registered and logged in to see this link.]

So...

A 1999 Pug Boxer Symphony petrol 2.0i, No MOT. We bought it on Feb 2017 and here's whats been done to the van since then:

27/02/2017    Oil & Filter, new front tyres, new leisure battery + MOT, habitation check. Done by JMT Leisure.
04/04/2017    Sort out rear brakes, change gearbox oil, lube clutch cable + fit air suspension rear
05/07/2017    Strip + clean front brakes, new clutch cable.
04/09/2017    Fix horn, replace Fan Belts.
21/09/2017    Reroute drain tube, check sink tap
23/10/2017    Replace RM S/O 5
04/11/2017    Replace exhaust + rubbers
28/11/2017    Replace engine + gearbox mounts
12/03/2018    MOT repairs + windscreen washer pump + MOT
09/06/2018    Remove drive shafts + replace oil seals
05/09/2018    Fit new N/S driveshaft, replace gearbox oil, new front tyres etc
26/10/2018    Rebuilt gearbox, clutch plate, clutch cable + O/S driveshaft
07/11/2018    Replace coil pack, HT leads, spark plugs
27/02/2019    MOT welding + MOT
10/05/2019    Replace fuel pump relay + repair wiring
08/10/2019    Replace O2 sensor, MAF sensor, fuel filter
03/12/2019    Robins & Day checkout ECU, can’t read, said scrap the vehicle!
26/03/2020    MOT + horn + replace ball joint.
28/05/2020    Replace front lower ball joint.
05/06/2020    Replace coil pack again (engine warning light now off).
13/10/2020    Inlet manifold gaskets leaking coolant into inlet, replace inlet manifold gaskets, drill and tap 2 8mm bolts in cylinder head - snapped on inlet removal. Inlet manifold removed again to pressure test coolant gallery - all tested ok.

Coolant temperature sensor resistance checked- out of range - changed - no difference in running.

Fuel injector amp clamp resistance checked on running injector 1 showing a fault. Injector changed for secondhand injector. Running much improved but still has intermittent flat spot under load.

All 4 injectors changed for secondhand units.… Better but again no power under load.

Saturday 09:00 to 14:00 access fuel pump set up pressure tester. Van driven while pressure monitored. No fault pressure consistent.

New plugs and leads....no change under load.

Cylinder head removed pressure tested and skimmed. Pressure test passed.
Rebuilt with new waterpump, timing belt kit, radiator and thermostat. Fault still present.

The fuel pump stopped working suddenly so pump removed from tank and tested and working ok.
Wiring diagram for fuel injection main relay sourced.

Next step is to check every wire to the relay and understand why the live feed to fuel pump is failing, wiring continuity checked live shorting to earth connection. Pump give live from battery and road tested. No change. Coolant temperatures sensors + coolant + thermostat. Machine shop cost and gasket set, skim head, pressure test. Passed. Timing belt kit inc water pump.

22/05/2021    Delivered back to us unable to repair.

If someone could fix the problem, then other things that need sorting include, sills and the electric hot water doesn't work (or at least heat the water). There will be other things as we've done hardly any miles in it since 2018! Basically since the gearbox was rebuilt (with new clutch). The MOT work dated 12/03/2018 also included patch welding to both sills.

The van is near Abergavenny.