Some years back my 2006 Ducato 2.8JTD motorhome suddenly lost a lot of power and started running rough in combination with the engine/injector red warning light coming on permanently (and would only switch off after turning the engine off and allowing it to rest for a few minutes). We limped to a dealer and after connecting it to the computer it showed No2 fuel injector had failed. (Note: in hindsight if I had known what the problems was, I could have wiggled the injector cables myself and thus find out which one was the faulty injector). Apparently it is a common failure (although it happens more often on No4 fuel injector) and apparently is the result of a too tight wire loom, causing a broken cable or poor plug connection. A 2nd hand connector with 20cm cable was obtained from a wreckers; the new plug fitted with a bit more slack in the cable and that should have been the end of the story.
Unfortunately after several thousands km’s of problem-less driving, the problem reappeared with the same injector. To make a long story short: what solved the problem in the end was to bend the 2 contacts in the engine block of that particular injector ever so slightly down and re-insert the plug. It apparently provides a better contact as its never happened again and we are now happily driving several years and many km’s down the road.
Unfortunately earlier this year the same engine/injector warning light started coming up again. However in a different mode this time: as opposed to being permanently lit, it would light up, but disappear when taking the foot off the accelerator. Initially it would only show when going up hill and having the accelerator in the top 10% of its stroke. However the situation worsened and the warning light started coming up whenever the engine had to work a little more than usual (fast driving and/or going up a slight incline). However never during urban driving and the light would always disappear once taking the foot off the accelerator or, if I kept pushing the engine, arriving at the top of the hill/incline.
An internet search eventually lead me to believe that, although it was the same warning light, this time it had nothing to do with the injector. Actually it turned out to be a Turbo issue. The waste gate valve (allowing the compressed air to enter the exhaust directly) was getting harder and harder to operate as a result of sticking/rust. This is more likely to happen if a vehicle has been stationary for a while (note: as my vehicle is a Motorhome it is not driven much (if at all) during winter). The waste gate valve can be found at the back of the engine: follow the exhaust towards the engine and you see a rod attached to the top of the turbo. A bugger to get to if you can’t elevate your vehicle, but a torch, a bit of WD40 or silicone spray and an adjustable spanner to manually operate the lever on top of the valve and a spare 15min will do the job.
Unfortunately after several thousands km’s of problem-less driving, the problem reappeared with the same injector. To make a long story short: what solved the problem in the end was to bend the 2 contacts in the engine block of that particular injector ever so slightly down and re-insert the plug. It apparently provides a better contact as its never happened again and we are now happily driving several years and many km’s down the road.
Unfortunately earlier this year the same engine/injector warning light started coming up again. However in a different mode this time: as opposed to being permanently lit, it would light up, but disappear when taking the foot off the accelerator. Initially it would only show when going up hill and having the accelerator in the top 10% of its stroke. However the situation worsened and the warning light started coming up whenever the engine had to work a little more than usual (fast driving and/or going up a slight incline). However never during urban driving and the light would always disappear once taking the foot off the accelerator or, if I kept pushing the engine, arriving at the top of the hill/incline.
An internet search eventually lead me to believe that, although it was the same warning light, this time it had nothing to do with the injector. Actually it turned out to be a Turbo issue. The waste gate valve (allowing the compressed air to enter the exhaust directly) was getting harder and harder to operate as a result of sticking/rust. This is more likely to happen if a vehicle has been stationary for a while (note: as my vehicle is a Motorhome it is not driven much (if at all) during winter). The waste gate valve can be found at the back of the engine: follow the exhaust towards the engine and you see a rod attached to the top of the turbo. A bugger to get to if you can’t elevate your vehicle, but a torch, a bit of WD40 or silicone spray and an adjustable spanner to manually operate the lever on top of the valve and a spare 15min will do the job.