Hi,need some help getting to the bottom of problem I've got with a 54 Doblo 1.9JTD. Engine was using gallon of oil a week,but ran ok,removed engine and top end u/s,customer got spare Y reg Punto JTD engine,as most parts/mounts were different, stripped to block only leaving injectors and cam sensor,rebuilt with new belt kit/gaskets and original turbo,pump,sensors etc from original doblo engine,refitted and started ok. Engine is very down on power,would hardly rev or pull,have swapped sensors with a running spare vehicle,blanked egr,got improvement when Maf was cleaned so swapped with one off perfect running vehicle,no better,swapped boost controller and vaccum controller,ran with exhaust disconnected incase cat blocked,swapped map sensor.On my code reader has come up with boost control circuit a fault,but only occasionally,clears and doesnt come straight back.Got a reccomended mobile tuner out,waste of money,couldn't read system fully.So advised customer I couldn't go any further with diagnosis and would need to go to main fiat dealer,which it did.They diagnosed egr faulty,replaced @£230 no better,then they advised boost control bleed off pipe wasn't connected to filter as connector broken on filter(been like this a year no probs as only bleed),so they fitted pipe @£33,no better,then it was turbo @£1400.I had advised customer that these would make no difference,at each stage,as he rang and told me what they'd found.Before the turbo was fitted I rang and spoke to garage and wasn't inspired by the service manager,but did get through to the master tech,who when he realised I wasn't a numpty had a sensible chat about what to do next,he checked it himself and fitted various parts as I had and concluded it must be the turbo as not much boost.Not convinced and in view of the cost the customer got it back and I fitted turbo off a running vehicle he had,just the same as before. It went to the Main dealers as I assumed they had access to readings and values that could be checked at sensors and pins,to see if it was a wiring problem or which sensor was giving faulty readings.They gave me the impression that they didn't have access to this info and the back up from Fiat technical was limited/poor. So I need to sort this as am at a loss as to where/what to do next,I could check readings values if I had them,vehicle is a working vehicle and has been off road for weeks now, so customer and myself getting desperate,not leaving any rope or sharp objects near me at minuteworked on these for years,guys got about 20 Doblos, but this has got me stumped,also doesn't smoke and idles fine,but occasionally while idling can hear engine note change slightly,Thanks for any help,John.

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with the last bit saying you can hear engine note change slightly i have noticed this before myself and it was to do with the MAF sensor plug. i am waiting for a new one as we speak and i can go out now to my doblo and fiddle with the plug on the MAF sensor and the pitch goes higher when its NOT making a good connectiona and seems to go LOW/DEEPER when its HAS got a good connection. i noticed no power from the turbo and it seemed to back off going through 3500 revs. everything was limited and slow.

found the problem fixed it temp (closed pins in on PLUG and cleaned pins on MAF and sensor) and everything just FLEW. really good power.

i know its this because i actually diconnected during a drive then connected it back up. amazing difference.

(and the smoking it did with the MAF DISCCONECTED - WOW!)

Eklipze3k said:

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PMSL

Why dont you try Desira, they are local to you aren't they?

Thanks,will recheck plug,but has had a Maf changed by dealer and then taken off as no difference,I would hope they would check resistences accross pins and condition of connectors,I've looked and sprayed with contact cleaner,white grease and reassembled ,they did look fine.
Local dealer it went to when I drew a blank was one of the Desira outlets,although not the local one to me as vehicle was away from base.
All input appreciated,I did speak to master tech there,who after a chat realised I wasn't joe public and we had a heart ta heart about problem,he advised he would've checked all I had,but did have an afternoon on it,with the final conclusion that it was the turbo,I've have swapped with one off a scrap vehicle known to run fine and no different.
Only thing not changed is injectors,but the mastertech queried the numbers and I advised had original injectors from vehicle and could supply or fit,he said he'd check numbers to see if different and said no more and concluded after checking turbo u/s.