Technical Fiat Ducato, 2004, Troubleshooting fuel system?

[dave333]

Hello

Need suggestions for troubleshooting the fuel system!
I have a Fiat Ducato from 2004, the diesel engine is called 2.0 JTD and has 84 hp.

Last summer the diesel pump broke down, a new pump was installed by Fiat.

After the new diesel pump was installed, a return hose started to come loose and leak diesel. At the same time, we think it is more tired than before and more black smoke. It is the return hose from the same injector that is leaking, I think it has leaked three times now.

Could it be that there is a problem with this injector? Or what could be causing it to build up pressure on the return side?

From what I have read, it should be 300 bar on the high pressure side and at least 0.5 when the ignition is on from the tank.

Please tell me which troubleshooting steps make the most sense! Thanks in advance!!!

 

[Communicator]

Hello

Need suggestions for troubleshooting the fuel system!
I have a Fiat Ducato from 2004, the diesel engine is called 2.0 JTD and has 84 hp.

Last summer the diesel pump broke down, a new pump was installed by Fiat.

After the new diesel pump was installed, a return hose started to come loose and leak diesel. At the same time, we think it is more tired than before and more black smoke. It is the return hose from the same injector that is leaking, I think it has leaked three times now.

Could it be that there is a problem with this injector? Or what could be causing it to build up pressure on the return side?

From what I have read, it should be 300 bar on the high pressure side and at least 0.5 when the ignition is on from the tank.

Please tell me which troubleshooting steps make the most sense! Thanks in advance!!!

I have not needed to do it myself. but if you are suspecting one injector a leak off test could provde confirmation.

 

[bugsymike]

Hello

Need suggestions for troubleshooting the fuel system!
I have a Fiat Ducato from 2004, the diesel engine is called 2.0 JTD and has 84 hp.

Last summer the diesel pump broke down, a new pump was installed by Fiat.

After the new diesel pump was installed, a return hose started to come loose and leak diesel. At the same time, we think it is more tired than before and more black smoke. It is the return hose from the same injector that is leaking, I think it has leaked three times now.

Could it be that there is a problem with this injector? Or what could be causing it to build up pressure on the return side?

From what I have read, it should be 300 bar on the high pressure side and at least 0.5 when the ignition is on from the tank.

Please tell me which troubleshooting steps make the most sense! Thanks in advance!!!

Probably help to know the engine series for a start.
Was the injector pump fitted by Fiat a brand new genuine one or a rebuilt one?
Depending on what engine , then the type of injectors and the retaining clips to secure the return pipes from them varies.
The engine needs approx. 230Bar as a minimum pressure from the high pressure pump before the ECU will open the injectors to run. When revved modern injection systems can exceed 2000Bar, so treat with respect!
Is the engine high mileage as injectors usually last for a long time.
A guide to injector general condition can be a "leak off" test this measures the volume leaking past the injector moving parts compared with the other cylinders. a small amount is normal , but if one is excessively higher it is a bad sign.
If engine turbo and intercooled then any loss of air pressure can cause black smoke.
It may be helpful to have any error codes read and "live data" if possible.