Hi everyone,

 

I’m dealing with a persistent issue on my 2016 Ford Galaxy 2.0 TDCi (150 PS, manual) and hope someone here had a similar experience.

 

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🧾 Car Info

 

• Model: Ford Galaxy 2.0 TDCi (Delphi system)

• Mileage: ~214,000 km

 

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❗ Symptoms

 

• Engine shuts off suddenly under full throttle at very low RPM (e.g. ~1,200 rpm in 6th gear uphill)

• After shutdown: long cranking, or needs 2–3 ignition cycles to restart

• Error occurs even with full tank

• Reproducible under those conditions

 

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💡 DTCs

 

• P008A / P228C – Low fuel pressure (low-pressure system)

• Occasionally: P0251, P02FA (once)

 

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🔧 What’s been done

 

• ✅ Fuel filter replaced

• ✅ In-tank pump/module replaced

• ✅ Low pressure sensor (FPSB) replaced – values are plausible

• 👁️ Visual inspection of fuel lines and filter housing – no leaks, clips secure

• ⛔ Filter housing not yet replaced

 

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🤔 My assumption

 

• No more electrical issues – sensors seem fine

• High-pressure system works under high rpm and load

• Issue occurs only at full load and low rpm → possibly suction issue at HP pump inlet

 

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❓ My questions:

 

• Has anyone had similar symptoms – engine shuts down at full load / low rpm?

• Could the fuel line DS7Q-9J280-BB be leaking air?

• Could a weak HP pump cause this (e.g. poor suction at low speed)?

• Would changing the IMV valve help – or is it pump replacement time?

 

I’ve Forscan logs including shutdown and restart attempts.

 

Any help or shared experience is much appreciated 🙏

 

Thanks in advance,

Thomas

Late night immediate stupid thought, gut feeling, preliminary answer... Leaks may not show up visually, use a Mityvac to test fuel lines under vacuum. Joints or filter housings, fuel heaters can leak (believe me)
Check demanded and actual fuel pressures and look for bubbles in fuel line if transparent section.
If not that, go to Plan B...

4 minutes ago, Shearers said:

 use a Mityvac to test fuel lines under vacuum.

thanks for you late night thoughts. I will test the pipes before ordering the next parts.

Suggest serious look at all relevant Forscan parameters and a lot of testing rather than just fitting expensive parts.

Replaced fuel filter housing last year due to starting issues - bubbles in fuel line noted but where was the leak?

A vacuum test across filter inlet with return pipe sealed showed a leak.

Then test across filter inlet and outlet showed same leak i.e. somewhere on filter housing - never found it visually. Each section needs isolating in turn if a leak is present?

I bought fuel line fittings to make some connections.

Otherwise Plan C or someone else's Plan?...

Edit: Leak off test?

Thanks for your reply.

 

I have a Forscan Logging, including the error and cranking / starting afterward.

 

You can find it here:  https://drive.google.com/drive/folders/1_FpTwt2yWcnrDBrmeyVenk36oVi_3Di0?usp=sharing

 

EDIT: problem starts at 30300 time (ms)

That is a heck of a lot of data which I would ask you to filter down and say what changes you note.
But first, I'd still make the actual visual checks for bubbles and perhaps vacuum testing (cheap vacuum pumps are on eBay - suggest you get one that does pressure as well as they are  very useful)

Otherwise, when the problem starts I'd look at demanded and actual fuel rail pressures and any other parameters that are out of range and confirm (maybe) that the rail pressure drops which it will if it's fuel starvation from an as yet unknown cause?

Unless there's another quicker plan?

3 hours ago, Shearers said:

That is a heck of a lot of data which I would ask you to filter down and say what changes you note.

my Interpretation of the logging:

1. Driving under full throttle at low RPM (~1260 rpm, 80% accelerator pedal position)
2. F_VCV_CUR (IMV current) rises to approx. 950–1050 mA
   → The control unit increases the current to the Fuel Volume Control Valve (IMV) during the event.
3. FRPS (Fuel Rail Pressure Sensor voltage) starts to drop steadily, while IMV current remains high.
4. Within ~1.5 seconds, FRPS drops to near zero, followed by engine RPM falling to 0 (engine shutoff).
5. After shutdown, the FPSB (Low-pressure fuel sensor) value begins to decline gradually.
6. On restart attempt: no immediate engine start, time gap in RPM signal suggests several ignition cycles were needed.    - Air in the System?

Vakuumpump is on the way. 

 

edit:

What struggles my mind, is this:  

 The pressure drop clearly starts on the high-pressure side, even though the low-pressure sensor drops only after the stall   

  Yet after shutdown, there is air in the system, which requires multiple ignition cycles to purge  

→ Can a pure high-pressure fault (e.g. mechanical failure of the HP pump) cause this type of air ingress? Or is there likely a combined issue (e.g. suction-side leak that only manifests under full-load/low-RPM conditions)?

Edited August 20, 2025Aug 20 by zerokewl
question added

Iff and only if I understand the issues (Ha Ha!)
I would say that, the results say you are demanding a lot of power at low revs, the control system tries to respond but, due to an air leak or something else, the injectors can't supply enough fuel, the rail pressure drops and, perhaps there is a cut off level at which the PCM  gives up?

If there's air (ARE  there any bubbles - massive clue!) when you crank it over then enough fuel needs to be supplied to the HP pump to allow it to start again.
If the pump lobes are breaking up, check for "glitter" in the filter housing and I think there is a spring in the pump that can break but that would more likely be a crank never start issue:
https://www.youtube.com/watch?v=GhQNCTrgsRk

A leak off test is another powerful diagnostic rather than just changing components i.e guessing?
https://www.youtube.com/watch?v=E89oncZcZgg
 I think some real inspection rather than going off the sensor clues is now needed.
I await your results with interest!

 

final Update: I made an Leak-off-Test. Zylinder #4 was leaking badly.

Replaced it => Error gone.

 

Thanks for your help.