Technical Comedy of Errors

[coffeebean500]

Hi all,
First time posting about my Ducato (I also have a 500). Purchased a 2012 3.0 180 Multijet to convert to a campervan. Let it mostly sit over the Swedish winter and that was a big mistake. Went to drive this spring and now have been dealing with a bunch of problems. First I had to deal with brake issues, then replace the fuel filter, then there was a short somewhere in the rear lights. Got those solved but I have a persistent engine light on with code P0262 (high voltage injector 1). The van starts fine and drives for a bit before the light kicks on and I guess it must go into "limp home" mode....and that's what I do. I took it to the local garage and they gave it back with no charge, said they don't think it is a bad injector, but that I should take it to the dealer and see about getting the ECU updated and/or flashed. I called the dealer and, without seeing the car, they quoted me about 1200 USD to replace injector 1 as that was "99.9% likely" to be the issue. Of course.

I think it is some electrical issue. I've dealt with crazy Christmas trees on my 500, and already solved some minor shorts and things with the van. So...today I decided to take apart every connector I could find under the hood, clean everything, check grounds, re-tape wires where needed, etc. I found a mystery connection hanging out over by the ECU. It appears to be a different mystery connector than the post from a couple of days ago, it looks like the same type of connection the EGR uses so I thought maybe it COULD be important, but I cannot find where it goes. Since I don't post much, I cannot post a photo or link here, but I did upload to imgur: /a/Y8y9nuO If anyone can tell me what it might be, that would be great, I cannot seem to solve this with my wiring diagrams. I realise it is probably from some option I don't have, but when you are looking for an electrical issue and you find a connector waggling about by your ECU, you wonder.

Happy to hear any suggestions about the error as well. I have read a ton of forum threads, here and elsewhere, trying different solutions. Will get the dealer to flash/update the ECU this coming week but I am trying to be proactive about the issue.

 

[coffeebean500]

Here is the link: https://imgur.com/a/Y8y9nuO

 

[Anthony489]

Hi Coffebean 500

Problems after lay up are often due to corrosion of electrical contacts. The injectors require a fairly high current pulse, so will not function properly even if there is only a slightly bad connection. The ECU can sense this for the individual injectors and throw an error code. As you don't get an error straight away, it suggests that operation is only marginally out of limits.


An auto electrical specialist can measure the electrical resistance of the injector without removing it. They can also check the wiring from the ECU to the injector and the connections. If you have a good ohm meter you can do this yourself, by measuring the resistance to ground of each injector. They should all be very similar, I would guess at one or two ohms.


I don't think your missing plug is the problem. As you say, it is probably an option not fitted on your vehicle. And it would be unusual for it to affect just one injector.

I also don't think any kind of software update or reflash will have any effect on the high current drivers in the ECU that operate the injectors.

If there is genuinely an injector problem, try adding injector cleaner to the fuel for a while.


If after all that you do decide that a new injector really is needed, a special hydraulic extractor is needed for removal. These have to exert an enormous force.

Good Luck

 

[Anthony489]

Slight correction to the above. I believe the Ducato uses Piezo type injectors rather than solenoid type. The resistance will be different, and it it not a DIY measurement. It is still possible for a specialist to measure the injector electrical operation without removing it from the engine.

 

[coffeebean500]

Hi Anthony489, thanks! I went ahead and used a multimeter and the ohm readings were...strange (184?!)...but injector one was DEFINITELY having problems, while 2-4 were about the same. So....injector. Now....the next problem. Used a penetrating oil on the retaining bolt and it still broke (never got the torque past 30 foot pounds..). I was prepared for that. I will go ahead and try to get the bolt out next, fun times. BUT, looking at the hole...I have a good 1.5 inches or more of space where I could just thread and fit a new bolt above the broken piece. I was concerned about the broken piece being in there if the retaining bolt goes into the water jacket, etc. but I cannot find any information that this stupid bolt is in anything other than a strangely long hole with the bottom part threaded. WHY BOSCH WHY?

 

[coffeebean500]

I just read on the Piezo type injectors and they should be between 150 and 210 kohms...so that solves that mystery!

 

[coffeebean500]

Oh, and also, I tried injector cleaner for the last few weeks and it did not solve the problem.

 

[IceVovo]

This may help you.

I have the x244 2006 2.8JTD VAN.

I discovered a major water leak onto my electrics under the bonnet within the first 3 weeks of ownership. Car was off the road being worked on.
This was a complete fluke...the discovery.
We had a LOT of RAIN ...all of a sudden.

...and I wasn't driving the VAN. What a fluke!
I could imagine electrics being blown everywhere if I was driving it.

I am unsure but your model may have the same leak in the same area?
I posted some photos.
You may want to find/fix waterleak!

 

[coffeebean500]

This may help you.

I have the x244 2006 2.8JTD VAN.

I discovered a major water leak onto my electrics under the bonnet within the first 3 weeks of ownership. Car was off the road being worked on.
This was a complete fluke...the discovery.
We had a LOT of RAIN ...all of a sudden.

...and I wasn't driving the VAN. What a fluke!
I could imagine electrics being blown everywhere if I was driving it.

I am unsure but your model may have the same leak in the same area?
I posted some photos.
You may want to find/fix waterleak!

It is always wet here, and moisture is certainly a problem. We have replaced the drain hose that is over the sensitive electronics, it was in bad shape and there was certainly moisture getting in. We took apart every connector we could find, no corrosion. Some of the wires were a bit wet, we let them dry, checked for corrosion, re-wrapped and reconnected it all. Still the same error when the engine warms up a bit.

 

[corcai]

Swap the injector to another cylinder see if the high voltage error moves.

 

[IceVovo]

I have not had to deal with an injector fault yet...

The injectors are coded?
Maybe someone installed it without the code?
It may just be the injector. They are a hard working part and don't last forever.

If you goto the trouble to remove the injector, you could probably get it tested when it is out?