General 2013 Fiat Ducato 2.3 130 multijet - smoking and struggling on hills

[Jswal]

Hi, please help. We've got a 2013 Ducato that has recently had a new DPF (old one had been smashed out by previous owner). Its had new sensors on DPF, new fuel pressure regulator and numerous other parts changed, but its still smoking when accelerating and engine management was coming on up hill before changing fuel pressure regulator. Its currently at a diesel garage in Essex, who have checked injectors etc which seem fine and they are stumped like us. Is there anyone out there whos had similar issues or has any idea whats wrong and where we go next? Thanks
Oh also a small piece of plastic fell in the air intake whist we were working on it, would that have an effect?

 

[Anthony489]

Hi Jswal . Smoke means too much fuel or not enough air. You seem to have checked the fuel side, so I suggest you take a good look at the whole air intake system to make sure there is no restriction or anything partly blocking airflow. This includes the throttle body and it's wiring.

 

[Communicator]

Hi, please help.

=======================================================
=======================================================

Oh also a small piece of plastic fell in the air intake whist we were working on it, would that have an effect?

Was it large enough to damage the mass airflow sensor?

 

[oigle]

Check your hoses for pressurised airleaks. Splits or loose connections.
Ian.

 

[Jswal]

Hi Jswal . Smoke means too much fuel or not enough air. You seem to have checked the fuel side, so I suggest you take a good look at the whole air intake system to make sure there is no restriction or anything partly blocking airflow. This includes the throttle body and it's wiring.

Hi Anthony489;4603411 thanks the response, apologies it was the inlet manifold that the plastic fell into. Throttle body has been changed. Garage now suspect that whoever smashed out the middle of DPF may have then remapped and thats causing issues now we have a new DPF. Its reading 60% blocked and won't do a full regen. Fingers crossed that is the issue, as everything else looks ok according to the garage

 

[Jswal]

Was it large enough to damage the mass airflow sensor?

Thanks, I got it wrong, it was the inlet manifold. I've been told apparently it shouldn't cause an issues

 

[Frank451]

Hi

I have same/similar issues for months/year. 2014 2.3.

Outline - white smoke/smells like unburnt fuel. Happens when tweaking accelator or when slowing down with throttle then reapplying throttle. Sometimes goes into limp (p0089 fuel pressure on injector support). Also does it when pulling away from roundabouts/slip roads, during take off or changing up down gears.

6month ago - had egr and cooler replaced and fuel pressure solenoid. Plus full service (independent garage). No change.

This week - sent to fiat commercial for diagnostics. Blocked pipe in Dpf to Dpf pressure sensor and faulty sensor. Also reported injectors 1&2 faulty. They wanted £2200+vat for this.

Took back to independent garage. They checked pipes on Dpf, not blocked (maybe fiat cleaned them through, but not convinced), change Dpf pressure sensor. Since collecting Dpf regen light has been on. Put injector cleaner in and 30litres of field. Drove round the M60 ring road 45mile. Regen didn’t finish as kept restarting when engine blipped (lack of fuel) smoked as usual. Had full limp mode with p0089 on a few occasions (rolling engine restart reset limp). Regen would restart. Had Multiecuscan running and Dpf clogging status is normal (41.67%) but regen keeps restarting even from cold.

Not 100% convinced injectors are faulty due to readings off Multiecuscan. Seems to be a good few posts on this over the years but no concrete answers.

Any help appreciated, willing to shell out on new injectors but don’t think it’s the reason, engine never rattles can run fine for longish periods other times can be stop start every journey.

 

[Jswal]

Hi

I have same/similar issues for months/year. 2014 2.3.

Outline - white smoke/smells like unburnt fuel. Happens when tweaking accelator or when slowing down with throttle then reapplying throttle. Sometimes goes into limp (p0089 fuel pressure on injector support). Also does it when pulling away from roundabouts/slip roads, during take off or changing up down gears.

6month ago - had egr and cooler replaced and fuel pressure solenoid. Plus full service (independent garage). No change.

This week - sent to fiat commercial for diagnostics. Blocked pipe in Dpf to Dpf pressure sensor and faulty sensor. Also reported injectors 1&2 faulty. They wanted £2200+vat for this.

Took back to independent garage. They checked pipes on Dpf, not blocked (maybe fiat cleaned them through, but not convinced), change Dpf pressure sensor. Since collecting Dpf regen light has been on. Put injector cleaner in and 30litres of field. Drove round the M60 ring road 45mile. Regen didn’t finish as kept restarting when engine blipped (lack of fuel) smoked as usual. Had full limp mode with p0089 on a few occasions (rolling engine restart reset limp). Regen would restart. Had Multiecuscan running and Dpf clogging status is normal (41.67%) but regen keeps restarting even from cold.

Not 100% convinced injectors are faulty due to readings off Multiecuscan. Seems to be a good few posts on this over the years but no concrete answers.

Any help appreciated, willing to shell out on new injectors but don’t think it’s the reason, engine never rattles can run fine for longish periods other times can be stop start every journey.

Frank451 sorry for the delay in replying, we've gone from black smoke to white?

Since last post we've had 4 new injectors as when they were tested they were failing miserably at 80% leak off. We've also had it remapped back to factory settings because as suspected it had been mapped to ignore the fact that the DPF had been gutted.
We now are fine driving it around town etc, but after 20mins or so of motorway driving it starts to smoke(white) as if doing a regen, but never manages to complete one.

 

[Frank451]

Hi jswal

Well I’ve figured out that after changing the Dpf pressure sensor and double checking the pipes and doing a static regen. Dpf was then down to 67% clogged.

Van ran fine for 194km mainly motorway test runs. Now clogging is back up to 81% and background regens started again. Causing the white smoke and some black when first accelerating. So Dpf is stuck in regen as it can’t complete due to the interruption with smoke/choking on itself.

Had leak off done after static regen and all 4 injectors fine. I suspect they won’t be now it’s in regen mode again. It’s almost like the fuel it puts in for the regen isn’t getting to where it needs to go and then causing the issue.

Apparently background regens start at 80% if these fail you will get glow plug warning light then if the regens fail for a number of times you will get the Dpf regen light on the dash.

All in all there is something a miss with the regen cycles just not sure what. I am going to install DPF monitor on a android phone and take for a drive to monitor what is going on, should be doing this tonight.

 

[Doobdo]

Hi I have quite the same issue. Since 6 month sometime our ducato start to smoke grey /white and until it has a a cough. Sometime i can run 1000 km without problem sometime i have it 3 time in 200 km. Today for my first time I have an engine light (p0089). I will change tonight my gasoil filter and had an injector cleaner. I ran during 2000km with premium diesel without issue. On my last reload, i used regular diesel and it happen again. How did you get out of it

?

 

[Popitinpete]

My monies on that little bit of plastic that fell in blocking or stopping something happening., can the plastic bit get to the EGR? Has it held it open/closed.