Technical 2.8 JTD cutting out

[nwsxp50]

Hi All,
I realise long distance diagnosis is very difficult but please try anyway. Travelling yesterday in my 2004 2.8 jtd Ducato based motor home. I was doing about 60mph up the M1 when the engine cut out. I coasted onto the hard shoulder. Tried the key and it turned over but wouldnt fire. I left it for about 30 seconds and it started. This happened about a dozen times in 100 miles. The return journey today all went went well until almost home and it happened again. Just the once. This also happened albeit twice about 6 months ago. The van has an after market inhibitor but I dont think its that. Whilst parked up yesterday I jiggled every plug I could find under the bonnet. Can this engine be plugged into a PC and fault codes be read and would they point me in the right direction? Any help will be gratefully received . Thanks.Simon

 

[T14086]

I would start looking at crank sensor & fuel delivery to begin with. Did engine light come on (stored code) ?

 

[nwsxp50]

Hi , Yes the engine light did come on. A couple of times the light came on but the engine was still running but seemed lacking power. Is there a limp home mode, does anbody know? Thanks. Simon

 

[notnug]

Hi simon,
You have the same problem as me it sounds ? when engine light is on it seems to only rev to 3200 rpm and seems to struggle to pull away but it will go .
To date I have replaced common rail, pressure senser, and now fuel filter compleate.
All with still joy, it will run all day on lower throttle pedal but as soon as you ask it to overtake swiftly the light comes on almost instantainally.
My one has a habit of conkin out in the fast lane !!!!!.
If I find a cure I will let you know, I am changing the compleate fuel pump tonight so will keep you posted if this cures it.
I have been told it could be fuel pressure regulater so ??? lets hope.

 

[notnug]

Ps,
mine stored a code in the brain of PO191, which was told by the bloke in the garage was a pressure senser fault so I got one n fitted it n but was NOT that a it stilll done it.
So its obviously before that somewhere in the system.
So dont waste ur money on one of them before getting it looked at properly, if you do need one I now have three which all work.

 

[nwsxp50]

Hi, This is the response I had on another forum. I hope it helps. I am intending to have this test done asap.

Yes your van has a diagnostic socket if it is a post 2002 vehicle. The most likely cause is a sticking injector. There are a number of other possibilities but this is in my experience the most likely. The way to get this checked is to perform a 'leak-off' test which most garages that handle diesel engines regularly will be able to perform. It takes about half an hour and is more relevant than plugging into the diagnostic kit because if the problem is intermittent it may well not show up as a fault when it is tested, but the leaking injector will be easy to spot when a test is carried out.

The 2.8JTD engine requires 300bar of pressure in the fuel rail before it will start, but this can drop as low as 230bar without the engine cutting out. If an injector is sticking intermittently it will almost always show signs of excessive back pressure as well and that is what you find with the 'leak-off' test. If the injector sicks open while the engine is running the fuel rail pressure will drop off severely and cause the engine to stop.

Like I said, this is only one possibility but it is the first thing that we check in our workshops and it is almost always the culprit.

If your chosen garage is not sure about how to conduct the test, let me know and I will send a procedure.

Good luck,

Nick

 

[John C S]

Further to the above thread, any good Bosch Diesel Injection specialist would be able to do this test. A normal garage would probably take it to a Diesel injection specialist anyway, so cut out the middleman.

 

[PeterM]

Hi, This is the response I had on another forum. I hope it helps. I am intending to have this test done asap. Nick

Thanks very much for getting back to the Forum, Nick. Your message will be of use to others. Please let us know the result of the test!

PeterM

 

[T14086]

PO191 is pressure regulator I think (need to check) if so just unscrew it, give it a clean & pop back in as this can cause cutting out intermittently.

 

[notnug]

PO191 is pressure regulator I think (need to check) if so just unscrew it, give it a clean & pop back in as this can cause cutting out intermittently.

Hi Mr T

I assume the press reg is the thingy on the end of the Hp pump ? not the sender unit on top of it ? :shrug:

Just an update, I have changed the whole diesel pump as I have spare engine with all bits on and yes to date its not thrown up the red engine warning light and its kept running.

I must admit I have not used the van for long trip yet but it only took 10 yards of floor down throttle pedal to bring up light n the prob so maybe its cured :slayer:

If you can let me know if its that on the pump I will strip it out and keep it for spares unless anybody needs one ?

Thanks
Andy

 

[T14086]

pressure regulator on pump, normally held in by 2 torx bolts.

 

[notnug]

Hi All
Well sorry for the late reply, laptop died so been offline

Well here it is the cure for all my worries , took the pressure reg off the high pressure pump and yes I found a rouge lump of something nasty wedged inside and able to move around and intermittantly cover the tiny hole in the reg.
Cleaned it up n refitted and hey presto job done...
So wasted money on parts that it never needed that was advised by garage that done obd fault code test on it, n gave my po191 code.
So in fairness to them I suppose it was kinda along that route as it blocked the hole and gave the same feeling as pressure loss in the common rail but all along it was a little bit o poop in the fuel line causing the problem.
It looks like when derv filter was changed it came loose and free from there somewhere and went on its travels through my fuel lines untill it came to a place it found it could not get any further along so then caused me all these problems , magagement light on under acceleration/ load, the feeling of fuel starvation, and intermittent cutting out in the fast lane !!!!.
So thanks to all you guys for all the ideas and especially Mr T its jobe done now ) .
Hope this might be of help to any one else who might need it .
So vans back in my good books again.