Hi there newbie here. I currently own a 2012 Fiat Ducato which seems to have developed a misfire when the engine is under load.. the revs drop for a second and resume to normal, followed by a bleep am check engine warning message. If I ease off the accelerator then the van will continue. However if I continue to push the accelerator then the van will misfire and eventually lose power and I have to bring the van to stop and turn ignition off and restart the van. This is an intermittent problem and does t store a fault log. I have also noticed that the van on occasion when started seems to idle rough and smokes. Not sure if these are connected any help or advice would be much appreciated thanks in advance

I'd get the fault codes read. I had a funny miss in my 3.0 diesel at lowish revs for ages which I couldn't find. Eventually it was found to be an intermittent failure of the glow plug relay. I was surprised to say the least as I thought they were only operative when cold. An upside was an improvement of about 8% in economy and no miss...worth a look for sure.

Ian.

sounds like an 02 sensor to me its mounted in the exhaust check the wiring harness to it first

Carl

But sounds similar to my old 2.3 120bhp euro4

Fuel pressure regulator, after a miss diagnose by a diesel specialist in Watford (reckoned it was injectors) after £4000 work it was exactly the same, re diagnosed by the garage who I took it to for injectors (the diagnostic place wouldn’t touch it as the inj bolts snap off which they did)

£120 pressure reg

But

Yes get fault codes read.

Also church 2 bottles of Forte diesel turbo cleaner in a tank and run the whole tank through, using the whole rev range,
Might be just egr/turbo system gunged up

Rolopolo has about all I diagnose wrong with it. But recon there's more than one problem. Fuel pressure regulator leaking would cause it not to start as pressure would not be attained to suit ECU and/or cause shutdown on booting it, but, there is this power drop to consider, so possible.
Forte cleaner, hope it clears the dribbling injector, somehow I think there will be a change.
EGR/Turbo gunged up, well not sure if its waste gate on this beastie of variable vanes, but gunge near wastegate causes power drop on booting, temp, full cutout is caused by fuel pressure.
Turbo actuator also to check for this power loss only.
Injectors drains to check for too much bypass of fuel on possible one.
Good Luck...

To be fair.. Carl in his original post says that it's an intermittent problem that does not store a fault code.. suggests he's had them read.. but I'd ask this of Carl regarding reading fault codes.. what device have you used to do this as many of the off the shelf types that say they read fault codes are limited in which modules they can communicate with and even then may be limited to the diagnostic info they can retrieve from the module(s).. and no different on fiat vehicles.. really ought to get it read by Multiecuscan or diagnostic expert.. that is, if you've used a basic reader !

When my fuel pressure reg went, it was intermittent, started fine, only when warm, and setting off at junctions it would often cut out, go into limp mode occasionally, warning lights etc, then once cold no errors. No leaks,

But deffo needs a proper code read/diagnostics check.

New Member joined due to same problem!!
I have a 130 multijet Maxi 2012 with only 38,000 miles.

When revs are only 1800 it misfires for only a brief moment almost like the ignition is turned of and on quickly. If I drop a gear and rev the gear through it is then fine. Occasional it says check engine and goes in limp mode, after a quick restart it is generally fine again. I have also noticed that when it has done its thing that it belches grey smoke for a good 10 seconds.

In the last week it has developed starting problems it is very long on the key. I have managed to book it in for analysis at a Fiat commercial dealer Wednesday this week. From my past experience with a Mercedes Vito that had a similar problem it had a fuel rail sensor replaced for only a few pounds. Hope this is something similar. I will post again with progress.

See here is the overlooked answer that Riggs mentions, garages would be rubbing their hands here. Doesn't start easy, shuts down on booting it, cruising to a stop with foot off accelerator (where did I hear that one) it shuts down. Looking into fuel pressure there looks like. No code or fuel pressure code. Better get the rail and injector bypasses checked for leaks.
Ahhhhh wait how about the Fuel Rail Pressure Sensor..
As I found out once before that their cheaper if Bosch from a Bosch distributor.
Renault Scenic 1.9dci sensor, £150 from Renault. £94 from Bosch.

And on it goes.... Just had Fiat dealer do analysis and its the injectors... all 4 of them. It shows high fuel rail caused by the injectors leaking back. The garage allowed me to stay with the mechanic so I witnessed the testing and do agree with their findings.

Quote given £1500 + vat plus there is a high chance that the injector bolts will shear off, If so they have to get a specialist in to drill out and re-tap. Further cost of £150 each bolt, 4 bolts perhaps £600 +vat.

Could be a £2,300 + bill.

It takes a little to understand this fully. Had been tempted to change it a few months ago for another, now having serious thought not to touch Fiat again and buy something else.

Dealer says this problem is mainly in the south of England and only effects Euro 5 engines. Just done an 80 mile trip and only did the cut out thing once.
All thoughts welcome.

Riggs2017 said:

And on it goes.... Just had Fiat dealer do analysis and its the injectors... all 4 of them. It shows high fuel rail caused by the injectors leaking back. The garage allowed me to stay with the mechanic so I witnessed the testing and do agree with their findings.

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Have they carried out a leak off test or are they just relying on a rail pressure reading from an electronic diagnostic check?

Quote given £1500 + vat plus there is a high chance that the injector bolts will shear off, If so they have to get a specialist in to drill out and re-tap. Further cost of £150 each bolt, 4 bolts perhaps £600 +vat.

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Have seen recent reports from the owner of a business running and maintaining a fleet of their own Ducatos on another forum. He recommends a liberal soaking of injectors and bolts with "Innotec Deblock Oil" for 2-3 days before dismantling. He reckons it has been very successful and has not had a single bolt break or injector seized solid since using it.

Hi, Yes they put the pots on and ran it all four were leaking badly. Had a local fuel injection specialist quote £1300 + vat using new injectors. They are also scared about the injectors sticking saying they have had a problem recently with a 2012 Ducato needing a hydraulic lifter that still took over 4 hours on each to extract. They have said that on top of the injector there could be up to £300 extra per injector if things do not quite go to plan. This could include drilling the injector out totally then a re-tap. Having a think overnight on the next action. Very frustrating as it is otherwise perfect.

Riggs2017 said:

Hi, Yes they put the pots on and ran it all four were leaking badly. Had a local fuel injection specialist quote £1300 + vat using new injectors. They are also scared about the injectors sticking saying they have had a problem recently with a 2012 Ducato needing a hydraulic lifter that still took over 4 hours on each to extract. They have said that on top of the injector there could be up to £300 extra per injector if things do not quite go to plan. This could include drilling the injector out totally then a re-tap. Having a think overnight on the next action. Very frustrating as it is otherwise perfect.

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Bennett’s in Watford (diesel injection specialists) diagnosed injectors on my 57 plate in early 2012,
Wouldn’t do it due to potential bolts snapping off,

A truck garage did the work

Bolts snapped

Injectors, work, cambelt and service
£4000

Started it up, same prob

And it turned out to be the pressure regulator £120

It is not likely to be all of the injectors if this is intermittent and runs of otherwise fine. Wiring or sensor is my bet, start simple, even a speculative sensor replacement, but always have proof that relevant connections have been opened and inspected at all connections.

andydiver said:

It is not likely to be all of the injectors if this is intermittent and runs of otherwise fine. Wiring or sensor is my bet, start simple, even a speculative sensor replacement, but always have proof that relevant connections have been opened and inspected at all connections.

Click to expand...

Just a couple of thoughts if you do need to go down the route of injector replacement. I would recommend trying the Innotec treatment. I have no reason to doubt the person who posted about his, indeed he has proven to be extremely trustworthy and knowledgeable over a number of years. At around £15 for a can it's got to be worth a try. The attached photos show an injector removed following treatment and two bolts, one treated and the other not.

Secondly, a number of companies now offer hydraulic injector removal services at around £100 per injector, and will come to your home or business to do it. Some appear to be more reputable than others, but this should be apparent from their websites, or asking around a few local garages who they recommend. It seems to me that it might be preferable to have the injector(s) removed at £100 a piece on your driveway and then pay for the van to be transported to a workshop for replacement if necessary, as it could well be cheaper than asking a garage to do everything, particularly if they are loading their quotes on the basis of the additional aggravation they expect to encounter.

I've just had this problem with my 2013 Ducato, after many false starts, the Fiat garage told me Ducato's have issues with the injectors, and because the bolts are awful, they'll probably need to be drilled out, which just happened to me, the specialist guy that does these says he's doing 35 Ducato's a month, anyway, 4 injectors later,and £1800 lighter, the problem seems to have been solved.