156 2.4jtd cutting out unusual issue
I have an unusual problem with my AR 156 SW 2.4 JTD 110kW. I have searched the web and found no answer to my issue. Please read carefully before posting the usual suspects.
The issue is that the engine cuts out while driving. It has happened a few times now and each time I felt a barely noticable judder (or slight hesitation) and after that the engine cuts out. The judder is so faint you are not even sure it happened but while you are still thinking about what has happened the engine dies just like it would be turned off.
Each time the ECU reports a "Fuel pressure regulator fault" and the car fails to start. As I belived this to be the fault I changed the fuel pressure regulator (used item) and cleared the fault and the car started up and behaved perfectly for the next 50km before the same thing happened again. Same FPR fault reported. Thinking that the used FPR might be the issue I changed it over for a second used FPR and a fuel pressure sensor and the car started again and it ran for 200km before clonking out again with the same FPR fault.
After that I suspected the crank sensor so I changed it with a new Facet item and I installed a third used FPR but this time the car didn't fire up immediatly. It took some cranking and after starting it ran rough like only 3 cylinders were working but after a few seconds the 4th and 5th cylinders joined the party and after that the car ran 500km before it died again with the same fault reported by the ECU.
After that I have changed the FPR to the second unit that clonked out on me after 50km and the car is now running for the last 200km... so obviously the FPRs are ok.
So I have a FPR fault that kills the engine but it is not the FPR itself that is causing the issue. I have done the following:
-changed three FPRs
-a new fuel filter was installed
-2 fuel pressure sensors
-installed a new crank sensor
-checked phisically the overflow of the injectors and they are perfectly equal
-checked the high pressure fuel pump for leaks and havent found any
-the car starts easly on crkanking so I predict there are no air leaks in the system
-car performs normally
-the EGR is blocked
-the ECU is running a stock 110kW map
-I have checked the wiring and the wires itself seem to be in order
-All the connectors were cleaned and sprayed with a contact spray
-there is no moisture aroung the ECU
-the low pressure in tank pump is running OK (if I unplugg it the engine stops but there is no FPR fault reported)
-I tried unplugging the cam sensor but the engine keeps running and produces a cam&crank sensor missmatch fault
-looking at the engine performace with the MultiEcuScaner showed nothing unusual. The fuel pressure reaches 1500bar at high RPM and is steady at low RPM. No fault are reported except a failure on the preheating circuit (faulty plug).
I belive the previous owner had a similar problem before selling me the car but before I got it the car had always started up normally after cutting out. I got the car on a trailer as a non runner but after clearing the FPR fault it cranked into life and worked like a charm for about a year and a half before it started acting up. I found no connection between acceleration, idling... and cutting out. Each time it happened it was on part throttle.