Technical 500 Diesel smokes with clanging

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Technical 500 Diesel smokes with clanging

So I decided was putting off trying to take out #1 injector as everything I read about the job seemed to require a special tool. I sprayed copious amounts of WD40 at the base over 2 days then loosened everything. A bit of a wiggle with an open end spanned and the damn thing came straight out. Bonus.

Looking at the injector it is definitely not new (as claimed by the previous owner), so I have sent it off to a specialist for testing and re-building if required. New ones are quite expensive over here (like $450) a check and clean is $95. If the injector comes back with a clean bill of health I guess the loom is next
 
So I decided was putting off trying to take out #1 injector as everything I read about the job seemed to require a special tool. I sprayed copious amounts of WD40 at the base over 2 days then loosened everything. A bit of a wiggle with an open end spanned and the damn thing came straight out. Bonus.

Looking at the injector it is definitely not new (as claimed by the previous owner), so I have sent it off to a specialist for testing and re-building if required. New ones are quite expensive over here (like $450) a check and clean is $95. If the injector comes back with a clean bill of health I guess the loom is next

If the previous owner was wrong about the new injector, may I remind you of my post #17 ? Its quite likely that the injector calibration codes in the ECU are wrong as well as an other issue. hek those before doing anything else. It's basic stuff that needs little effort. If you are getting into deep fault finding you are going to need Multiecuscan anyway.

Robert G8RPI.
 
Sent the injector off for testing, report is that the base has a crack and it is not sealing inside. The injector was continually leaking diesel into the cylinder. The company are re-building it and in a couple of days it will be returned fully re-furbished. They predict that being the Bosch injector that was originally delivered it may not need re-calibration. Hopefully this is the case, but if not then I will most likely have to get a mobile diesel specialist out to do the diagnostics.
 
Got the rebuilt injector back, and installed, the reading remained the same so it did not need re-calibrating (?). Installed and now wont start, it kicks a bit, then runs for a second and cuts out. lots of cranking before it gets to the fires but cut again stage. It does sound smooth when it does catch but it just wont stay running.

I have added 1/4 tank of new diesel as the gauge was getting toward empty and the diesel in the tank has been there at least 6 months now. I removed the fuel filter element -which looked OK, but will replace it with a new one just in case. Only other thing I can think of is an air leak in a fuel line somewhere.

Oh, number 2 injector makes a very faint regular very faint ticking noise when the ignition is on (no cranking) just ticks like the needle inside in opening and closing quickly, its just number 2 not any of the others, is this normal??
 
I hear the pump activate when I turn the key to ignition, it hums for a short time which varies as I assume it has to build up pressure, then stops when I assume the pressure gets to the correct level. just waiting for a new filter now.

The ticking of #3 is odd though
 
I hear the pump activate when I turn the key to ignition, it hums for a short time which varies as I assume it has to build up pressure, then stops when I assume the pressure gets to the correct level. just waiting for a new filter now.

The ticking of #3 is odd though
That sounds normal behaviour for the in tank pump, it runs for set time when ignition turned on to prime main pump. It then runs again while engine cranking on starter and runs continuously when engine running.
Yes clicking injector when engine not running very odd, disconnect the electrical connection to that injector and see if engine will start on 3cylinders.
 
Got the rebuilt injector back, and installed, the reading remained the same so it did not need re-calibrating (?). Installed and now wont start, it kicks a bit, then runs for a second and cuts out. lots of cranking before it gets to the fires but cut again stage. It does sound smooth when it does catch but it just wont stay running.

I have added 1/4 tank of new diesel as the gauge was getting toward empty and the diesel in the tank has been there at least 6 months now. I removed the fuel filter element -which looked OK, but will replace it with a new one just in case. Only other thing I can think of is an air leak in a fuel line somewhere.

Oh, number 2 injector makes a very faint regular very faint ticking noise when the ignition is on (no cranking) just ticks like the needle inside in opening and closing quickly, its just number 2 not any of the others, is this normal??

hi there my friend ! have the same issue 2009 model 180.000klm.Did you solve the problem?i am close to bankruptcy (new dpf,multiple oil changes every 4 months,multpiple diagnosis etc)
 
Hello, sadly I got so annoyed I sold the car. The man who bought it wa a Fiat specialist, he got it running by drilling out the DPF which was blocked, and told me all of the other 3 injectors were no good. Over here it costs $500 each to re-condition an injector so I sold it at a loss. There is a Chinese auction site selling compatible injectors for about $200 each
 
Hello, sadly I got so annoyed I sold the car. The man who bought it wa a Fiat specialist, he got it running by drilling out the DPF which was blocked, and told me all of the other 3 injectors were no good. Over here it costs $500 each to re-condition an injector so I sold it at a loss. There is a Chinese auction site selling compatible injectors for about $200 each

thx for the answer my friend!i am in love with my 500 so i will try to cure it! i really dont believe its a matter of the injectors , i would have problems all the time not just when it regenerates DPF.My DPF is new so i dont belive its that problem either.we ll see....
 
Hello, sadly I got so annoyed I sold the car. The man who bought it wa a Fiat specialist, he got it running by drilling out the DPF which was blocked, and told me all of the other 3 injectors were no good. Over here it costs $500 each to re-condition an injector so I sold it at a loss. There is a Chinese auction site selling compatible injectors for about $200 each

Thanks for coming back to update this thread - I'm sorry to hear you had to sell at a loss.

Sadly modern emissions control systems and high pressure common rail fuelling have changed older diesels from being an economical workhorse into an expensive liability. DPF's, EGR's and injectors have a design life of around 80,000-100000 miles, and replacing them all would by then likely cost more than the value of the car.
 
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