I was in Morocco and a breakdown was long overdue (my van breaks down every 2 or 3 years on average).
Normally it’s an easy fix by the side of the road, but this time was different.
This time it was a failed fuel pump (Bosch VP30). This is the point where most people would scrap the van due to the expense and/or complications of replacing it. But I can’t do that. It’s my home.
In this post we’ll go through how my van broke down, what the symptoms were (with fault codes), the diagnosis and how I got back on the road with my van running better than ever…
Also see this post: Stranded: How this Moroccan scrapyard became home for 3 Weeks
Driving through the mountains to Paradise Valley
When the van broke
The engine suddenly cut out with no warning. Will not start
It can’t be fixed here
This is the first time I’ve not been able to fix it by the roadside.
Abdullah took us to his garage in Aourir
They shared their dinner with us
They thought it was the timing
But I had a horrible feeling… it’s the fuel pump!
My van (LDV Convoy) shares the same engine as the Transit; Ford Durtorq 2.4. These engines are great apart but after so many miles they all suffer this common problem: diesel pump failure (Bosch VP30).
Fault codes P1665 and P0216
3 days went by living on the roadside
We moved down the road to Ali’s garage
Better than the roadside at least
The problem is the mosfet driver inside the pump’s electronic controller unit (PCU)
Possibly because of failed insulation to the solenoids
We repaired the cables to no avail
They tried to make a frankenstein pump out of broken ones
Weeks went by
Most diesel engines in Morocco have mechanical fuel pumps rather than electronic. None of the mechanics had the knowledge or equipment to diagnose and fix electronic pumps. At this point I realised I’d have to order a new pump from Europe.
I ordered a new pump. If this doesn’t work the van is done for
Hassan fits it
The pump comes ‘viginised’ – no programming needed
Change the clutch while we’re here
For an extra £50 Hassan changed the clutch (I provided the parts)
And fix all those leaks
Whilst we have the van in pieces we might as well fix those oil leaks that have been there for years! A new front and rear oil seal.
Thanks to Ali and Hassan!
Honestly, these guys will do whatever they can to help. There’s just no way you’d ever get this kind of service in Europe.
If you have a van with a faulty Bosch VP30
- Cheap option: pump PCU repair. Around £80 on Ebay but if you want long-term reliability this is not a good option.
- The best option: get a new pump. Choose this option if you don’t want to encounter this problem for another 20 years. A refurbished pump is fine but it’s best to get one with a brand-new PCU module fitted (you cannot do this yourself, it must be factory calibrated). If you’re in the UK try pfJones (https://www.pfjones.co.uk/ford-transit-2.0-2.4-td-tdi-tde-2000-2006-reconditioned-bosch-vp30-diesel-pump-0470004012.html)
Why is Morocco THE place to break down in your van?
- Skilled mechanics who repair first and replace second.
- Amazing service and will always go out of their way to get the job done – I’ve had many experiences now like this in Morocco only.
- Labour is cheap, even with tips and tourist prices.
- Most things are worth fixing to them – including old vans. I love this mentality.
But the problem is, even though Morocco has plenty of great mechanics, when it comes to diagnostics and digital electronics, it can start to get difficult. Here’s what I found:
- Many vans were shipped to Africa with manual fuel pumps instead of electronic because of market demand – they’re easier to fix and more reliable. This makes getting an electronic pump in Morocco is very difficult, even second hand.
- Moroccan mechanics don’t have much expertise, or equipment, to deal with electronic fuel pumps. For example, these pumps must be programmed/paired with the van’s ECU for them to operate. The garages and mechanics I dealt with wasted a lot of time finding used pumps, waiting for delivery, fitting them, only for non of them to work in my van. They even combined parts from different fuel pumps together to make a ‘good one’ without realising that, even if the pump is functional, it will never work if it’s not programmed to the van.
Anyway… the result is, my van is now running better than ever, MPG has improved, oil leaks fixed, new clutch feels solid without slipped on hills. I was so confident that I decided to drive far into the desert.
