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Old 25-11-2018   #1
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Non Starting Doblo Cargo 1.9 Multijet

Hi Everyone, Long time reader but first time posting. I've searched the forum and found similar problems, and over the last few months i've been following the solutions, but non have worked and so I'm posting this in the hope that somebody can help?.

I have a non starting Fiat Doblo 1.9 Cargo Multijet on a 55 plate, and up to about 4 months ago it was running fine, then it began taking more and more attempts to start, often requiring several cranking attempts before it would start after which it would run from the first turn of the key all day, even when cold, until the next morning when it would be hard to start again.

Then one Afternoon, it just cut out at some traffic lights and wouldn't restart, and upon lifting the bonnet I found that diesel was leaking all over the engine. This was traced to a perished leak off pipe running between the end of the injector tops to the black fuel manifold box, which had swollen and become to wide for the connecting barb. This was replaced, along with the leak off pipes running across the tops of the injectors, and normal running was resumed, and the starting issue disappeared.

This lasted for about a week, when the hard starting returned, and then one morning it just refused to start at all, eventually flattening its battery and a booster pack. There were no error codes logged, so I tried replacing the most obvious things first, replacing the fuel filter, Fuel pump relay and then the Battery, but the problem still wasn't solved.

The in-tank pump is running and there is a good flow of diesel being pumped through the filter and into the intake side of the HP pump, but according to the running parameters the rail isn't seeing the pressure it needs to start during cranking. So I then replaced the following:-

Rail Pressure Sensor
PCV Regulator Seals replaced (Green and white washers on the spindle)
PCV Regulator ( New Bosch unit)
All low pressure fuel lines
Replaced metal high pressure Fuel Line between the HP Pump and Rail
Removed and cleaned EGR Valve

I've also done a physical leak off test on each injector using 4 bottles and tubes, and all fill slowly to within one mark of each other, there is no huge gush of fuel to indicate that there is an injector are stuck open.

(Cambelt was replaced and a Brand New set of Glowplugs fitted at the Start of the Year)

Non of the above have got it running, and there are still no fault codes logged with each attempt, then I noticed this weekend that despite the Starter Motor sounding like it is cranking fast and the Battery being brand new and fully charged, the cranking speed shown on the Software never seems to go much above 220 - 230 RPM. So my first question is, whether this constant upper cranking speed is OK?, as I'm sure that I read somewhere that the Fiat Diesel's need to crank above 250 RPM before the ECU increases the fueling and activates the injectors?. Is there any Truth in this? or is it just internet pub talk!?.

I also notice that during cranking the Battery Voltage hovers around 10.5v and often dips under 10v, after a couple of starting attempts from being fully charged. I admit that I bought a cheap Calcium style battery to replace the one which was on the Van when I bought it, but it has the same Capacity (60AH) and CCA (540A) and is the same size and i'm no wondering if its not up to the Job. I charged and refitted the old battery and even tried them both together (linked via Jump Leads) but the results are around the same.

After chasing after a fuel issue, Could it be the Starter Motor or Battery which is still at fault?. I've uploaded and linked to two screenshots showing the various parameters during two start up and cranking sessions to see if anybody has any suggestions?

https://ibb.co/2tQYF55

https://ibb.co/qNWhQ8b


In all honesty after trying to get it going again for nearly 3 months i'm ready to just throw in the towel, scrap it and replace it with another cheap van as a runaround, but bodywork wise its still in very good condition inside and outside compared to the endless dented rot boxes and builders' vans that i've looked at replacing it with, and having paid to get it ply lined a month before it started playing up, i'm a bit reluctant to give up on it! and so any help would be appreciated.

Thanks in advance
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Last edited by ChrisJ1973; 25-11-2018 at 18:46.
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Old 4 Weeks Ago   #2
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Re: Non Starting Doblo Cargo 1.9 Multijet

hi i'm not a mechanic but i do know i've had similar problems,i resolved mine by changing the fuel cut off switch just in the pilar drivers side page 69 of the doblo handbook,i think mine was faulty if you haven't checked this it's worth a try
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Old 3 Weeks Ago   #3
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Quote Originally Posted by ChrisJ1973 View Post
Hi Everyone, Long time reader but first time posting. I've searched the forum and found similar problems, and over the last few months i've been following the solutions, but non have worked and so I'm posting this in the hope that somebody can help?.

I have a non starting Fiat Doblo 1.9 Cargo Multijet on a 55 plate, and up to about 4 months ago it was running fine, then it began taking more and more attempts to start, often requiring several cranking attempts before it would start after which it would run from the first turn of the key all day, even when cold, until the next morning when it would be hard to start again.

Then one Afternoon, it just cut out at some traffic lights and wouldn't restart, and upon lifting the bonnet I found that diesel was leaking all over the engine. This was traced to a perished leak off pipe running between the end of the injector tops to the black fuel manifold box, which had swollen and become to wide for the connecting barb. This was replaced, along with the leak off pipes running across the tops of the injectors, and normal running was resumed, and the starting issue disappeared.

This lasted for about a week, when the hard starting returned, and then one morning it just refused to start at all, eventually flattening its battery and a booster pack. There were no error codes logged, so I tried replacing the most obvious things first, replacing the fuel filter, Fuel pump relay and then the Battery, but the problem still wasn't solved.

The in-tank pump is running and there is a good flow of diesel being pumped through the filter and into the intake side of the HP pump, but according to the running parameters the rail isn't seeing the pressure it needs to start during cranking. So I then replaced the following:-

Rail Pressure Sensor
PCV Regulator Seals replaced (Green and white washers on the spindle)
PCV Regulator ( New Bosch unit)
All low pressure fuel lines
Replaced metal high pressure Fuel Line between the HP Pump and Rail
Removed and cleaned EGR Valve

I've also done a physical leak off test on each injector using 4 bottles and tubes, and all fill slowly to within one mark of each other, there is no huge gush of fuel to indicate that there is an injector are stuck open.

(Cambelt was replaced and a Brand New set of Glowplugs fitted at the Start of the Year)

Non of the above have got it running, and there are still no fault codes logged with each attempt, then I noticed this weekend that despite the Starter Motor sounding like it is cranking fast and the Battery being brand new and fully charged, the cranking speed shown on the Software never seems to go much above 220 - 230 RPM. So my first question is, whether this constant upper cranking speed is OK?, as I'm sure that I read somewhere that the Fiat Diesel's need to crank above 250 RPM before the ECU increases the fueling and activates the injectors?. Is there any Truth in this? or is it just internet pub talk!?.

I also notice that during cranking the Battery Voltage hovers around 10.5v and often dips under 10v, after a couple of starting attempts from being fully charged. I admit that I bought a cheap Calcium style battery to replace the one which was on the Van when I bought it, but it has the same Capacity (60AH) and CCA (540A) and is the same size and i'm no wondering if its not up to the Job. I charged and refitted the old battery and even tried them both together (linked via Jump Leads) but the results are around the same.

After chasing after a fuel issue, Could it be the Starter Motor or Battery which is still at fault?. I've uploaded and linked to two screenshots showing the various parameters during two start up and cranking sessions to see if anybody has any suggestions?

https://ibb.co/2tQYF55

https://ibb.co/qNWhQ8b


In all honesty after trying to get it going again for nearly 3 months i'm ready to just throw in the towel, scrap it and replace it with another cheap van as a runaround, but bodywork wise its still in very good condition inside and outside compared to the endless dented rot boxes and builders' vans that i've looked at replacing it with, and having paid to get it ply lined a month before it started playing up, i'm a bit reluctant to give up on it! and so any help would be appreciated.

Thanks in advance
Hi. Is it still with you?

Charlie
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Old 3 Weeks Ago   #4
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Re: Non Starting Doblo Cargo 1.9 Multijet

Quote Originally Posted by varesecrazy View Post
Hi. Is it still with you?

Charlie
Its a few days away from being disposed of, as i've now replaced it with another Van as getting a Diesel specialist to come out to it would probably cost twice what its worth.

The offending Van is about to be collected after Xmas by a Salvage Yard, and turned into a small cube of scrap. Can't wait to be rid of it now

Quote Quote:
hi i'm not a mechanic but i do know i've had similar problems,i resolved mine by changing the fuel cut off switch just in the pilar drivers side page 69 of the doblo handbook,i think mine was faulty if you haven't checked this it's worth a try
Sadly not, that was one of the first things I checked. But thanks for your suggestion.
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Last edited by ChrisJ1973; 3 Weeks Ago at 21:12.
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Old 3 Weeks Ago   #5
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Re: Non Starting Doblo Cargo 1.9 Multijet

Does it go on easy start..

If it was purely struggling rail pressure due to low revs..
Then any kind of decent revs ( through towing.. or a substitute fuel source) should get the injection working
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Old 1 Week Ago   #6
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Re: Non Starting Doblo Cargo 1.9 Multijet

Crank shaft sensor 30 solved my dead doblo, similar probs to you.
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