Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

[solarjakee]

Hey there so I need to replace a fuel injector on my van and I've removed air intake manifold etc in order to gain access to it. From what I'm reading the next step is to disconnect the fuel pump relay in order to lower pressure in fuel lines but the problem is I can't find it.

Does anyone know how to identify the fuel pump relay, or have a diagram of the fuse box on a 2001 1.9TD? Or does anyone know if there's another way of lowering pressure to fuel lines in order to safely remove the injector? Or can the fuel injector on a diesel be safely removed without lowering pressure anyway?

Any help would be greatly appreciated. Cheers

 

[Peter Pick-Up]

Welcome at FiatForum.

No need to take of the relay connection.
Just unbolt the fuellines, maybe some fuell will come out, but not much.
Remember to use compressed air to clean the injector surroundings, and use a lot of penetrating oil to loosen the injector clamp.
Also use carburetorspray to soften carbon build-up, specially if one, or more injectors (seals) were leaking...use it a lot, and let it seep down the injector mounting hole.
Let it soak for a few days, and use it agian during lifting the injectors out.
Sometimes it can be very hard to free an injector, do the following, unbolt the clamp but don't take the bolt of yet, start the engine briefly, compression will free the injector in most cases.
Anyway, take your time, and use a lot of compressed air, penetrating oil and carburetorspray.

Good luck.

 

[coffeebean500]

Welcome at FiatForum.

No need to take of the relay connection.
Just unbolt the fuellines, maybe some fuell will come out, but not much.
Remember to use compressed air to clean the injector surroundings, and use a lot of penetrating oil to loosen the injector clamp.
Also use carburetorspray to soften carbon build-up, specially if one, or more injectors (seals) were leaking...use it a lot, and let it seep down the injector mounting hole.
Let it soak for a few days, and use it agian during lifting the injectors out.
Sometimes it can be very hard to free an injector, do the following, unbolt the clamp but don't take the bolt of yet, start the engine briefly, compression will free the injector in most cases.
Anyway, take your time, and use a lot of compressed air, penetrating oil and carburetorspray.

Good luck.

Responding to this old thread because I am about to attempt removal of injector 1 on my 180 3.0 2012 Ducato. I broke the bolt already, luckily it broke about two inches into the hole and I was able to rethread the existing hold and put a strong, new M10 bolt in place. If I want to try letting the engine free the injector, I should just loosen the bolt a few turns or how much? Then, should I turn the engine over and immediately off, or turn on for a few seconds, or what? Some more details for someone who has never attempted diesel injector replacement would be much appreciated. Thank you!

 

[jackwhoo]

I would run the engine up to normal temperature then switch off then remove injector clamping fixings then see if it can be removed.

 

[coffeebean500]

I would run the engine up to normal temperature then switch off then remove injector clamping fixings then see if it can be removed.

Unlikely without force. The thing is quite rusty. I can try that, but when that fails, what's the best way to see if the engine can help me out?

 

[jackwhoo]

If its so bad you can't get it to move at all with a warm engine then you are going to need special tools and or special ist help.
You could try warning engine , seeing if it will move, starting engine with loose, but not removed retaining bolt, but don't damage cylinder head it will quickly get very costly.

 

[coffeebean500]

If its so bad you can't get it to move at all with a warm engine then you are going to need special tools and or special ist help.
You could try warning engine , seeing if it will move, starting engine with loose, but not removed retaining bolt, but don't damage cylinder head it will quickly get very costly.

I ordered the "official" tool, we will see how it goes once it arrives. Cheers!

 

[jackwhoo]

I ordered the "official" tool, we will see how it goes once it arrives. Cheers!

I commend you on taking the sensible course of action(-:

While waiting for tool apply atf or your favourite penetrating oil frequently between injector and cylinder head

When you get the official tool please post a picture.

 

[coffeebean500]

I commend you on taking the sensible course of action(-:

While waiting for tool apply atf or your favourite penetrating oil frequently between injector and cylinder head

When you get the official tool please post a picture.

The "official" tool (as in the service manual I have) is like this:
https://www.ebay.com/itm/263562087571

Will report on my success when it arrives.

I bought a can of rust removal spray stuff and have been using that. Is there something better that is easily sourced?

 

[coffeebean500]

This is what I have been using:
https://www.biltema.se/bilvard/smor...IsqHkyTAOhG_aaKeCbnjDggpueNwzU9EaAn5VEALw_wcB

Sorry, in Swedish.

 

[jackwhoo]

This is what I have been using:
https://www.biltema.se/bilvard/smor...IsqHkyTAOhG_aaKeCbnjDggpueNwzU9EaAn5VEALw_wcB

Sorry, in Swedish.

No don't say(-: sorry I like Swedish.

Unless you can squeeze the juice from the mythical golden toad of Nepal during the first full moon following the spring equinox then penetrating oils are broadly Similar.

 

[jackwhoo]

I followed the link and what you have may actually be better than the toad juice, just keep using what you have

 

[coffeebean500]

No don't say(-: sorry I like Swedish.

Unless you can squeeze the juice from the mythical golden toad of Nepal during the first full moon following the spring equinox then penetrating oils are broadly Similar.

Unlikely, but we will see how it goes with the current stuff. FIAT wants 12,000 Swedish kronor (approximately 1200 Euros) to change out the ONE injector. Big "no" on that one.

 

[coffeebean500]

Update: the tool arrived, was WAY too big for the injectors. Even though I had confirmed my vehicle with the seller. Sent it back and ordered:
https://www.expondo.se/msw-avdragare-foer-diesel-injektor-9-delar-10061066

Was happy to make that exchange, nearly 200 euro for the first, second about 50. The tool from Expondo arrived and it fit, but, I kid not, one end of the slide hammer had not been threaded. Unbelievable, the tool was useless. AMAZINGLY, the M10 thread cutter I bought to use on the injector mount bolt hole (where the bolt broke) was the correct size for it and I was able to cut the threads myself and put the thing together.

5 pulls and the injector came out. Cleaned things up a bit and slapped the new one in. Tightened it up with the brand new shiny M10 bolt and started it up. Runs like a champ and the error did not reappear.

 

[Pugglt Auld Jock]

So happy for you that this all worked out well. Now a days you so often hear of disasters where people have failed to extract an injector. There are a couple of companies here in UK who have made a whole business out of shifting seized in injectors. They come to you with their fully fitted out mobile workshop but the cost is - Phew! probably cheaper than stripping the head off though.
Thank you very much for letting us know how it went and the tools you used.