Technical 2007 Ducato randomly cuts out from loss of rail pressure 2.3 multijet

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Technical 2007 Ducato randomly cuts out from loss of rail pressure 2.3 multijet

Ciaranfox09

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Hey guys, sorry that my first post here is asking for help but I am at my wits end batteling a cutting out problem with my 2007 Ducato.

I have had the van for roughly 5 years and have spent thousands trying to fix this problem and being none the wiser.

Recently it has got so bad the van is no longer safe to drive as it can cut out completely as if the key has been turned off multiple times after a short distance. Previously this problem was very intermittent as I might happen once every 6 months.

Originally a local garage replaced the rail pressure sensor after that failed to fix the problem the van was taken to a diesel specialist who fitted a replacement high pressure pump. This also failed to resolve the problem and I was advised by the diesel spechilist it also needed 4 new injectors. I was surprised by this but they are a very reputable company in Ireland so I proceeded in the hope that finally the problem would be finished with.

Not long after getting the van back the problem reoocured same as before I reasoned that it must be some sort of electrical problem and took it upon myself to check the usual ducato wiring areas such as the fuse box under the bonnet. I also replaced the pressure control valve and rail pressure sensor again to no avail.

Most recently the van was taken to a diagnostic specialist he experienced the problem with all his diagnostic gear connected and could see that the pressure regulator was trying to compensate for a loss of rail pressure as it was happening the only conclusion he could draw from this was to start back at the injectors again.

To describe the fault it happens under light throttle espichally on a back road around 50 mph at transient throttle (on and off) never under full load and rarely in lower gear then 5th. It cuts out completely as if someone switched off the key no limp mode the engine actually stops running. It will restart instantly and drive prefect there is no shutter stumbles or misfires just straight cuts out and then can be restarted by just flicking the key on and off. The only fault is a P0089 for fuel pressure.

Also the throttle body was replaced with the updated unit on the advice of a fiat mechanic.

If anyone could help it would be most appreciated I am thousands of euro out of pocket and none the wiser as to what to do.
 
Hi Ciaran

I can't help with Fiat specifics at the moment, but I found that this presentation was a useful guide to common rail diesel operation: http://vu67.ucoz.ru/toplivnaja_sistema_dvigatelja_evro-3.pdf

Normally, things which work OK and then suddenly stop are associated with electrical issues, such as damaged looms or bad connectors. However, I have a suspicion that the Ducato engine management system is programmed to cut off the engine to prevent damage in an extreme situation. For example if fuel pressure gradually gets too low, at some point it will pass a threshold and the engine will be deliberately cut off. Thus a fuel related problem which is changing gradually can appear like a sudden electrical problem, if that makes sense.
 
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