Technical 2002 Doblo 1.9 JTD 8v misfire after rebuild

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Technical 2002 Doblo 1.9 JTD 8v misfire after rebuild

ozzy Doblo

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hi all, i've posted this in the Doblo forum, but thought that some of you Stilo guys may have some idea too 'cause of the JTD connection :slayer:

i'm hoping to gain wisdom and insight with a challenge i've got! :)
so, briefly, we have a 2002 doblo 1.9 jtd ELX car, owned for 5 years.
had 54,000 miles when bought, now got 108,000 miles on the clock (although the ECU says 125,000 ! :eek:)

car details (if it would be helpful)
engine type - 182B9000
bodywork code - 223AXE1A02
chassis code - ZFA 223.000
ECU is a Bosch EDC15C7 CF3/EOBD
BTW, i have Fiat ECU Scan + interface and it does not show any errors.
(the ECU thinks everythings fine - it lives in La La land :D)
Injectors are Type 2 - 28209

now, the problems -
1) over the past 18 months it has been smoking more and more (blue smoke - engine oil level creeping down), and power has been reducing.
2) as it got worse, it was using around 2 litres of engine oil every 600 to 800 miles :(
3) as it got colder, it was harder to start.

so, i decided to 'do'something about it -
1) i had the four injectors checked, one was out of tolerance, the other three were 'OK'. - nochange.
2) battery eventually died - replaced with new.
3) checked glow plugs, only 2 working well - replaced all 4 and kept the 2 old as 'spares'
4) compression test - cylinder pressures varied from 280 to 320 psi - not very good.
put some oil down the cylinders and retest compression - a small improvement, up to about 330-350psi.

so, first conclusions drawn were - possible wear on valve stems / valve guides, and worn piston rings / bores.

action - wait for 'summer' :cool: then commence major surgery....

so 'summer' is here (aparently :D),
creamup,
on with the latex gloves,
eyes down for a full house...

after dissembling (?) the head and removing pistons - i found the valve seats needed re-grinding, the valve seals needed replacing, the piston rings were 'WORN' down past the chrome layer etc.

so the work was carried out -
1) hone the barrels
2) replaced 4 sets piston rings
3) replaced valve seals
4) re-ground valves
5) re-assembled with clean oil, new gaskets etc
6) set valve timing
7) refil all vital fluids
8) turn key...

and it started to run with a 'misfire'.
it is not smoking like it used to though
redface.gif

so, one by one i removed the injector connectors, and tried to start the engine.
i found that number 4 connection removed made no difference to the running of the engine, but no's 1 to 3 connectors would prevent it running.

so i thought it was an injector problem.
removed no 4 and no3 injectors, swapped round and reconnected everything.

the problem stayed on no 4 cylinder.
so now i believe that the problem is with the wiring/electrics for no 4 injector plug.

i've got a multitester and understand some of the auto electrics, but most of my experience has been on petrol motorcycles, this is my first diesel.;)
i've looked through both google, this forum, the alfa owners website (same engine in some) etc and not yet come across much info on this specific issue.

has anyone got any idea if i can test the plug and wiring some how?
what voltage or readings should i get?
so, i'll attempt to trace the wiring back to the ECU to check for a break
and i'm going to check the compression on no 4 cyl, just in case.

any other ideas?
help and advice please?:confused:

thank you!

austin
 
Hello Austin,why not try some nord lights on the offending injector harness plug to see if its feeding the injector solinoid.I dont think you can swap an injector like that because each one is coded to the ecu.Were are you i have some nord lights you could borrow?
 
hi there buster and T14086,

thanks for taking the time to read and for replying :)

i had considered getting hold of a noid light, buster, so thank you for offering to lend one to me ;)

and yes, the injectors are type 2, so they are not coded. they work in any of the positions and the ecu does not display any correction factor for them in FiatEcuScan.

the problem is now sorted (y), i've updated the original post (link is here - https://www.fiatforum.com/doblo/277332-2002-doblo-1-9-jtd-8v-misfire-after-rebuild.html )

i should have updated this post too, sorry!

you could take a look at the things i found if you fancy :D

the engine is running well,

thanks again to all who followed and contributed!

austin
 
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