Hi, just done a quick search of the forum in case this is a common fault but I didn't find anything.

I have a 2003 Scudo EL 1868 CC.

Driving home yesterday I noticed a strong smell of diesel.

I've had a look underneath this morning with the engine running and diesel is dripping continuously down the front of the engine block more or less in line with No 2 cylinder (2nd from the left).

The leak is so severe I had to switch the engine off (which stopped the dripping).

There's no way I can take this vehicle out on the road so I can't get it to a dealer to be repaired (nearest one is about 20 miles away).

I'll have to fix this fault myself on the drive or else get on to a dealership to come out with a transporter to take it in for repair (which I don't really want to do for such an old vehicle).

Anyone any idea where it could be leaking from? I've had a poke around underneath and under the bonnet with a torch but can't see where the leak is coming from?

I suspect it's coming from somewhere behind the fuel pump, unless it's the pump itself?

Thanks in advance

DVD

Ok, I've done some more investigations and it appears that fuel is leaking from the base of the fuel injector on No 2 cylinder (2nd from left when looking into the engine compartment).

It looks really difficult to get at, I can hardly see it let alone get to it.

It's stuffed underneath the inlet manifold right behind the fuel pump.

Is this much of a job to fix? Is it something I can do myself or does it need to go in to a dealer?

I've changed a clutch in the past and reground the valves on a petrol engine (carburetor) but I've never messed about with a diesel injection engine before.

I've heard that when you replace a diesel fuel injector(s) you have to have the timing re-done as well, is this true?

Thanks

DVD

Take parts off in way I think these ones screw out need a big socket

Hi there, are you sure its the injector that's leaking?? It may well just be the fuel return pipe that links between each injector that's split. If it is, a replacement kit can be bought quite cheaply. The biggest job then is getting at them to simply swap over. Ive recently done my glow plugs and the most painstaking job is actually getting to them to swap. Took me about 2.5 hours in total. Hope this helps.

superscudo said:

Hi there, are you sure its the injector that's leaking?? It may well just be the fuel return pipe that links between each injector that's split. If it is, a replacement kit can be bought quite cheaply. The biggest job then is getting at them to simply swap over. Ive recently done my glow plugs and the most painstaking job is actually getting to them to swap. Took me about 2.5 hours in total. Hope this helps.

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Hi suerscudo

Where can I buy the replacement kit you mention? From a Fiat dealer or is there a generic kit that fits any/most diesels. Do you know/have a part number for the kit?

This morning I have removed the upper (plastic) part of the inlet manifold so I can get at the injectors and glow plugs etc.

Having looked at the engine I think you could be right about the leaking return pipe(s).

I think I can see the pipes you refer to. They are insulated rubber ones that go from one injector to the next. There is a pipe at the end that comes from the last injector on the right but it doesn't go anywhere, it's just blanked off by a screw that has been forced into the end of the pipe.

I doesn't look right to me. I think someone has bodged this job up in the past.

Do you know where this pipe should connect to?

See pic attached, I have highlighted the pipe with white arrow.

Thanks

dvd

Buy them off ebay the end one is blanked off they must of lost this one so used a screw as u say rob

Hi DvD, yes the fuel return pipes come as a generic kit and as R Masters says the end one should just be blanked off. I bought mine from the local motor factors but u can get them off e-bay too. As mentioned before, its actually more of a ball-ache getting to them than it is to change them over. Good luck and have fun with the repair.

Hi superscudo

Sorry, I tried to reply to you the other day but every time I logged into the site it booted me out again?

Yes I got a leak back pipe kit for about 3 quid I think it was.

Whilst I've been poking around the engine of this Scudo I've stumbled across all sorts of faults which have required fixing.

One of the glow plugs was open circuit so I decided to replace all four given I had gone to the trouble of taking the plastic inlet manifold off. This probably explains the poor starting over the winter.

Also the O rings on the manifold were rotten so I replaced all of those as well.

There are all sorts of pipes and air ducts which have been rubbing against each other so I have air leaks, potential fuel leaks and water leaks that need fixing.

There is a black plastic air duct which looks like some sort of water or dirt trap. It goes down the front of the engine from the EGR valve. This ducting has been rubbing against a water pipe and has now got a big hole in it [air duct]. So it appears the engine has been sucking air through this hole instead of through the air filter.

There is a transparent plastic fuel pipe that comes out of the fuel filter and goes across the front of the engine block, this has been rubbing somewhere and will need replacing.

The water pipe that goes from the top of the radiator to the expansion tank was leaking so I have done a temporary fix using a length of 10mm copper central heating pipe. It looks a bit naff but at least I'm back on the road. I'm going to get some propper 10mm water pipe today (Monday) and do a permanent repair job on it.

All being well that should just about cover everything?

dvd

dick van driver said:

Hi superscudo

Sorry, I tried to reply to you the other day but every time I logged into the site it booted me out again?

All being well that should just about cover everything?

dvd

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superscudo