Just bought a 52 plate 1.9 diesel Punto van. Well happy.Got a problem though. The previous owner explained that when she is cold and sometimes when warm she wont tick over and sometimes judders when driving. Van will cutout and engine management light will come on.did happen to me on way home now also sparks from exhaust. Someone told me to give her a hammering incase it was a build up of s**t etc that could be sparks problem so not to worried about that. Just the idling problem. Pevious owner said he has had it plugged in and no codes. He has blanked off EGR valve and changed maf sensor but how much is true i dont know. Passed MOT last month in this condition no issues with emissions. Has anyone got any ideas ? Will give more info if i can. Many thanks in advance. Tony:bang:

all sellers are liers so plug it into a code reader that can work on this for starters consider a fiatecuscan download and elm lead but you would need to check compatability

are you sure this engine will work properly with egr blanked off?
sparks?

Don't know about get to be honest. How do I reconnect it ? Sparks I've been told is sh*t from engine or muffler degrading cause she's been standing a while and I gave her a blast. Just come back now after a spin and not sparking now. Cheers for reply.

How do I reconnect it

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sorry no idea never had one

Ok mate cheers. Google it is then if I don't get another reply. Thanks anyway.

if the EGR is blanked off then usually you just stick a metal plate between the EGR and the Engine but if its been completely removed then you're a bit screwed (have to find a new one)

if it have been blanked off given your other faults it makes me wonder if its been done to hide a EGR sensor fault which can often be fixed by just cleaning the valve out with carb cleaner and effort.
on a different note how many miles has it done? when was the cambelt and water pump done ?

124000 mate. I'll check on the valve after work tomorrow and respond accordingly. Couldn't tell you about belt and water pump mate. Not sure if it makes any difference but I've got the van punto.

The seller told me he blanked it off as a trial for the issues that the van has but couldn't be sure if made any difference or not though !!!!!!!!

Is it the 1.9 jtd or 1.9 non-turbo diesel?

1.9 non turbo version mate.

themadwelshman said:

1.9 non turbo version mate.

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Common point of issues is the mechanical high pressure fuel pump. The internals wear which means the ECU can no longer make any adjustments to correct it, and it'll cause all kinds of running problems/lack of power/stalling.

If it's coming up with "Rotor position" as an error, the only fix is to replace the pump. Be careful with buying anything reconditioned- I've known even genuine Fiat pumps to flag up the same fault immediately on start-up once fitted (the Technician who did it wasn't impressed at having to do the same job twice ).

Ok mate cheers. Hoping to get plugged in next couple of days. Will update as necessary. Many thanks.

www.fiatecuscan.net

Cable and adaptors -
http://www.ebay.co.uk/itm/ALFA-FIAT..._Equipment&hash=item3a6eaab002#ht_1228wt_1092

The adaptors are not 100% necessary but they are foolproof and well worth the few ££s extra.

Edit:
You also need a laptop or netbook PC

Mentioned the cambelt and water pump as its always worth getting them changed if you don't know when they were last done but this was completely separate to the issue your having

Many thanks for replies so far. Much obliged. Will try to get more info on belt and pump. Cheers. Never thought. Looked at cables and adapters. Thanks for that.

On another note today I noticed white smoke from exhaust when under load. I was towing trailer. Also coughs and splutters when in low revs high gear assuming this is part of the same problem. I will try to keep updating as I get to know more.

update after ecu scan


Bought elm 327 lead off the bay and downloaded fiatecuscan but my van coudnt be done with thefree version so picked a couple of other vehicles with same engine and got same readings.

They are

P0510 Idle Control Sys (6) signal high stored fatal
P0252 Injection Pump Rotor/Cam

and at the bottom of the page it said

CLOSED Throttle Position Switch Malfunction....The fault is not detected now but is stored in memory and observe for future appearance of the same fault.Dashboard light was not activated for this fault.

RIGHT THEN. Now what do i do and where do i go ? :worship:

Also after looking under the hood to see if there was something obvious i foun this problem. see atteched photos. Looks like seapage on the injector from the rubber hose and around the bottom where the thread is. any suggestions ?

just found out this is my engne code if it helps anyone.

188A3000
cheers

The throttle position error will be to do with the unit mounted immediately after the airfilter (where a MAF would usually be). It should have an electrical connection and a vacuum pipe running around to a valve round the back of the engine.

The function of the throttle flap is to partially close under normal cruise/low load conditions to enable a higher concentration of exhaust gas to be drawn through the EGR and improve emissions. Under full throttle, the vacuum is released and the throttle flap should be fully open. The electronics inside relay the position to the ECU. There is no MAF on the 1.9d.

If the flap is sticking closed, the engine will effectively be choking on exhaust gas all the time, as well as being restricted for airflow at the top-end. However, you say the previous owner blanked the EGR? If he has, you should be able to see the plate he's put in. If it has been blocked off successfully, the only issue you'll be left with is the airflow restriction in the throttle chamber. It would be worthwhile to take this off and ensure it's open.

The idle control system fault may be due to you artificially holding the idle rpm high by cable tie-ing the pedal down slightly.

The Pump/cam rotor fault will be the issue I mentioned earlier, which has no fix other than a new pump. I wouldn't replace it until you've confirmed the throttle chamber isn't your main problem.

A word of warning- reading the error codes via the 'wrong' ECU can throw up incorrect data. By all means try to read the codes from other models with the 1.9d (Doblo is the only one I can think of), but don't try any of the TD/JTD models as the ECU is completely different.

Regarding the injector leak- try to see where it's coming from with the engine running. The rubber leak-off pipes can degrade and split over the years, but the other cause of leakage can be from the metal union itself, usually if people have not re-tightened it fully after trying to bleed air out. The 1.9d is an arse to work with as the upper inlet section is one-piece with the cam cover and covers two of the injectors, making checking them a pain.

Now then Danny boy. That's what I call a reply. Got somewhere to go now. I will finish work early tomorrow and make a start trust me. Handy being self employed sometimes. I will keep you informed as things progress. Cheers bud.

Cheers mate. Checked sensor by air filter. Seems ok move flap by hand and I can hear relay clicking so not broke off. Anyway of checking movement with engine running ? Flap is fully open at moment ? Leakage was top union loose on injector. Think that's sorted. See over next day or so. Where is this throttle chamber you mention mate ? Really obliged for your help in this.