Register Login
endrop - for all your online needs
Reply
 
Thread Tools Search this Thread
Old 21-12-2017   #1
Join Date: Dec 2017
Posts: 1
Thanks: 0
Trader Rating: 0
United Kingdom 
Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

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
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

solarjakee is offline Reply With Quote Quote 
Old 21-12-2017   #2
Moderator
Join Date: Mar 2008
Posts: 4,918
Trader Rating: 0
Peter Pick-Up has donated!
Russia 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

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.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides


Last edited by Peter Pick-Up; 21-12-2017 at 22:13.
Peter Pick-Up is offline Reply With Quote Quote 
Old 2 Weeks Ago   #3
Join Date: Jul 2019
Posts: 27
Thanks: 3
Trader Rating: 0
Sweden 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

Quote Originally Posted by Peter Pick-Up View Post
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!
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

coffeebean500 is offline Reply With Quote Quote 
Old 2 Weeks Ago   #4
Join Date: Apr 2017
Posts: 2,305
Thanks: 158
Trader Rating: 0
United Kingdom 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

I would run the engine up to normal temperature then switch off then remove injector clamping fixings then see if it can be removed.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

jackwhoo is offline Reply With Quote Quote 
Old 2 Weeks Ago   #5
Join Date: Jul 2019
Posts: 27
Thanks: 3
Trader Rating: 0
Sweden 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

Quote Originally Posted by jackwhoo View Post
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?
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

coffeebean500 is offline Reply With Quote Quote 
Old 2 Weeks Ago   #6
Join Date: Apr 2017
Posts: 2,305
Thanks: 158
Trader Rating: 0
United Kingdom 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

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.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

jackwhoo is offline Reply With Quote Quote 
Old 2 Weeks Ago   #7
Join Date: Jul 2019
Posts: 27
Thanks: 3
Trader Rating: 0
Sweden 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

Quote Originally Posted by jackwhoo View Post
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!
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

coffeebean500 is offline Reply With Quote Quote 
Old 2 Weeks Ago   #8
Join Date: Apr 2017
Posts: 2,305
Thanks: 158
Trader Rating: 0
United Kingdom 
Quote Originally Posted by coffeebean500 View Post
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.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides


Last edited by jackwhoo; 2 Weeks Ago at 15:47.
jackwhoo is offline Reply With Quote Quote 
Old 2 Weeks Ago   #9
Join Date: Jul 2019
Posts: 27
Thanks: 3
Trader Rating: 0
Sweden 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

Quote Originally Posted by jackwhoo View Post
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?
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

coffeebean500 is offline Reply With Quote Quote 
Old 2 Weeks Ago   #10
Join Date: Jul 2019
Posts: 27
Thanks: 3
Trader Rating: 0
Sweden 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

This is what I have been using:
https://www.biltema.se/bilvard/smorj...EaAn5VEALw_wcB

Sorry, in Swedish.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

coffeebean500 is offline Reply With Quote Quote 
Old 2 Weeks Ago   #11
Join Date: Apr 2017
Posts: 2,305
Thanks: 158
Trader Rating: 0
United Kingdom 
Quote Originally Posted by coffeebean500 View Post
This is what I have been using:
https://www.biltema.se/bilvard/smorj...EaAn5VEALw_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.
Likes Pugglt Auld Jock liked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

jackwhoo is offline Reply With Quote Quote 
Old 2 Weeks Ago   #12
Join Date: Apr 2017
Posts: 2,305
Thanks: 158
Trader Rating: 0
United Kingdom 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

I followed the link and what you have may actually be better than the toad juice, just keep using what you have
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

jackwhoo is offline Reply With Quote Quote 
Old 2 Weeks Ago   #13
Join Date: Jul 2019
Posts: 27
Thanks: 3
Trader Rating: 0
Sweden 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

Quote Originally Posted by jackwhoo View Post
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.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

coffeebean500 is offline Reply With Quote Quote 
Old 4 Days Ago   #14
Join Date: Jul 2019
Posts: 27
Thanks: 3
Trader Rating: 0
Sweden 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

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...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.
Thanks Pugglt Auld Jock, jackwhoo thanked for this post
Likes Pugglt Auld Jock, jackwhoo liked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

coffeebean500 is offline Reply With Quote Quote 
Old 4 Days Ago   #15
Join Date: Oct 2017
Location: Edinburgh Scotland
Posts: 2,191
Thanks: 204
Trader Rating: 0
Pugglt Auld Jock has donated!
United Kingdom 
Re: Need help changing fuel injector on 2001 Fiat Ducato 1.9TD.

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.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Pugglt Auld Jock is online now Reply With Quote Quote 
Reply
Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump
Similar Threads
Thread Thread Starter Forum Replies Last Post
(T) fiat ducato 2001 1.9TD brake bleeding sequence charris13 Ducato 1 17-07-2017 19:43
(G) Wiring diagram/manual 2001 Ducato 1.9TD vsherouse Ducato 4 18-06-2016 21:28
Info on 2001 Fiat Ducato 2.8 Injector Hornetboy Newbie Central 0 17-07-2009 06:35
Newbie in town! Fiat Ducato 1.9td 2001 wheelrim Newbie Central 0 23-03-2009 11:54
(G) Ducato 1.9TD 2001 Bad starter & Smokey sparkyvan71 Ducato 0 07-03-2009 21:29