Technical Issues P0191

[AnetteA]

Hello! Maybe someone had these same issues?
Had a Ducato 2.3 2004 mod (chassis 244) for 2 years now, no trouble. Went to neighbour country Sweden last weekend, filled the tank with diesel (almost empty) and then stopped right after. Minus degrees and the car wouldn’t start. Then a real problem sound, and we stopped. Red check engine lamp on. Tried a few times, then the lamp disappeared. Drove about 300m to the ferry. Well back in Norway we drove about 30 mins.
Tried diagnosis at home, P0191. At first it said injection fail, then pressure unit control and a problem with the ECU at one time. The diesel filter was loose, and full of water! Think we filled water that last gas station. And with the cold, can something have frozen? Checked the FRP sensor, nothing seems wrong with wiring. Could it be those sensors on fuel filter? Or maybe the injector? I don’t know. It seems like with 1500 rpm it just stop. But with 3-4000 rpm it seems good.

 

[bugsymike]

Hello! Maybe someone had these same issues?
Had a Ducato 2.3 2004 mod (chassis 244) for 2 years now, no trouble. Went to neighbour country Sweden last weekend, filled the tank with diesel (almost empty) and then stopped right after. Minus degrees and the car wouldn’t start. Then a real problem sound, and we stopped. Red check engine lamp on. Tried a few times, then the lamp disappeared. Drove about 300m to the ferry. Well back in Norway we drove about 30 mins.
Tried diagnosis at home, P0191. At first it said injection fail, then pressure unit control and a problem with the ECU at one time. The diesel filter was loose, and full of water! Think we filled water that last gas station. And with the cold, can something have frozen? Checked the FRP sensor, nothing seems wrong with wiring. Could it be those sensors on fuel filter? Or maybe the injector? I don’t know. It seems like with 1500 rpm it just stop. But with 3-4000 rpm it seems good.

I would start by checking 100% no more water in fuel tank, then flush system through and replace fuel filter and check it is tight with no leaks, I would then run the outlet from the fuel filter into a container and check again for water.
Obviously water will freeze, but if water has got into fuel it can create bacteria which can block system, also if summer diesel still in tank it can wax up with cold weather.
Also if you get it running happy again I would check the drain on fuel filter to see if any water collecting again as not unkown.
It pays to only get fuel at busy large fuel stations with a high turnover so less likely to be dirty.

 

[AnetteA]

So an update on this issue.. apologize for my poor English
New diagnostic reading says now;

P0191 diesel pressure control
P0204 cylinder 4 injector
P0606 control unit faulty microprocessor

We emptied the diesel and checked further for water. New diesel in and a bottle of injector / condensate clean. New fuel filter.
Checked the fuses connected to the fuel pump, and relay T10. All good there, tested with similar relay. Checked that switch above the battery, that had tripped out actually.
You can hear the pump when it fill up the fuel filter. But when I start and it stops again, I need to wait 15 sec before you hear it fills up again. Then it can run for a bit, but it comes a really rumbling sound and then ignition off!
-Can it be dirt somewhere, because we were almost empty when we filled up at the gas station (and then the water in). Almost like it doesn’t get diesel after I start up.
-Can it be wire connections that leads to all this errors, we had mice in the RV in oct.
- can it be the FRP sensor troubling? I loosened it and just put it back in. Is there two of them!? (I read that it is one on the high pressure side, looks the same.. or did I read that wrong).

I’m so grateful for input on this! Really hope it’s not the high pressure pump or injector change. That’s a stiff price here in Norway

See the attached file for type ducato 2,3 jtd 2004
Thanks, Anette

 

[bugsymike]

If fuel line noisy is there air in system?

 

[AnetteA]

If fuel line noisy is there air in system?

Thought the same. I can hear rumbling sound like air when the filter fills up. But that disappear after a few times…

 

[Jockstrap]

Maybe a bit basic. Attach a clear tube engine side of the fuel filter and suck fuel to check for air and/or sludge.

Could be a hole and air coming in as pressure increases?

Daft but a thought.

 

[bugsymike]

I have had earlier Fiats that rely on the high pressure pump to "suck" the fuel from the tank, as in no electric lift pump at tank, draw air from the plastic connection on the end of the pipe where itr clips onto tank unit.
Although in your case any leak with having an electric lift pump should push fuel out rather than let air in.
Either way I would definately check for air in the system.
Any air in a diesel system will cause problems, so a careful check all along the fuel system from pipes, filters assembly , sensors, fuel rail, injectors and even at the high pressure pump.
Sometimes just running a clean tissue may show it.
However do it with engine off as the high pressure leak may look like a fine mist, but can pierce the skin meaning hospital !!!