Taken it back to the local injector specialists who have removed and tested each injector and all 4 are showing faults so need replacing.
Is it normal for a diesel that has done under 60K miles to have all 4 injectors fail? or could something have caused this? What life span should I expect from an injector?

Fuel quality is key all that lubricates the injectors at thousands of pounds per square inch is the diesel. They could fail in a few seconds in the presence of water and wear rapidly with illegally stretched diesel containing kerosene alcohol etc.
Particles from wearing in the hp pump can be at fault too. if you haven't had it from new I would also consider it may be clocked.

Hi I had problems with a 2009 2.3 and even Fiat were lost they at first said the egr then injectors of which they replaced 2 then fuel pressure regulator,crankshaft sensor, maf sensor, throttle valve, fuel filter housing etc there was £1000's spent on it Fiat paying a good whack of the money, then an auto electrician took the ecu off and sent it to the ecu doctor in Plymouth and they cloned another ecu for plug and play and the motorhome is now running smoothly as a 20000 mile engine should, maybe you should get ecu tested it could be worth the £50 to put that out of the theory
Best of luck mate

Forgot to say my injectors were tested and they said 2 would need replaced but after trying to remove them and breaking studs the head came off new timing belt and gaskets fitted and it was still the same Fiat were lost !! ?

Maff172 said:

Taken it back to the local injector specialists who have removed and tested each injector and all 4 are showing faults so need replacing.
Is it normal for a diesel that has done under 60K miles to have all 4 injectors fail? or could something have caused this? What life span should I expect from an injector?

Click to expand...

No, it is definitely not normal! And it may also not be true.
After 60K miles there surely is some wear when comparing the injectors with new ones, but that does not mean they have to be replaced.

My van has done more than 60K miles, for at least 80% running on heating oil ("red diesel") and has no injector issues. And it better stays that way because I doubt it will be possible to remove them after 7 years of water ingress and salt deposits.

Hi, Any news on your Ducato?
I have 2005 2.8JTD and the symptoms are pretty similar.
Suddenly engine stops, red motor light comes on.
Waiting ~30s power off and then you can start it up normally.

Well, after having the injectors replaced last year (still not resolved the problem), recently replaced the pressure regulator, still playing up.

Low down :

1) Will cut out if put under strain at between 2500 and 3000 rpm with code P0191. Only happens when fuel in tank has warmed up (which makes it thinner)

2) Will happily pull uphills if kept above 3000 rpm (i.e. High gear)

Have come to conclusion HP pump may be cause but diesel "experts" don't think so. Have replaced Injectors, Regulator, Cam sensor, Maf sensor, Filter, pressure sensor. All with no joy.

Reread this thread and discovered the feed pump in the fuel tank is never mentioned....
At 2500-3000 rpm and full throttle you are in the maximum torque/maximum fuel flow area.
With the ignition key turned on or going downhill there is about 5 bar pressure at the fuel filter entrance because no fuel is consumed. If the flow is restricted or the feed pump tired, there may not be enough fuel available for the HP pump to reach the requested pressure.
With warm fuel the pump capacity drops considerably.
(You wrote somewhere that weird ideas were welcome.....)

Good thought. Have fitted a brand new Low pressure pump but it's still playing up.

Battery terminal loose.


It sits with a junction plate that clips onto the battery top. Notorious for becoming loose, but feeling initially that it is tight due to the clip. Lift the clip, the terminal will probably be loose.


The HDI/JTD requires 12v for the injectors to open. No voltage, no go.


Check this in case it is something that simple. Had it on my van when I bought it, luckily I knew, so I saved a few grand on purchase price.