Technical 2015 Ducato 115 Multijet Engine Stops Randomly

[AlfA01]

Hello!

I'm inquiring for some ideas/assistance in troubleshooting a used Fiat Ducato that I purchased recently. I drove the car for a month problem free and then suddenly the engine just shut off without warning as I was driving. I restarted the engine thinking I had forgotten to downshift and had accidentally stalled the engine due to load. A couple of days pass and the problem occurs again. This time it was accompanied by audible clicks from around the diesel pump. The clicks occurred more often and after some time the engine stopped and failed to restart. I was stranded on the highway an hour away from home.

The technician that troubleshot the car said the engine started again after unplugging and re-plugging the ECU. Almost immediately the problem reoccurred. The technician then decided that changing the high/low pressure valves on the diesel engine pump would remedy the problem. It seemed to be fixed until today. I have been driving the Ducato for probably two weeks trouble free and accumulated approximately 1600 Km's whilst doing so. I'm scratching my head to see what the problem could be.

Download shows a code 0094 which refers to a leaking diesel system, which is why we started with the valves. There is the audible clicks from the pump/valves.

Any help would be greatly appreciated.

Thanks
Dan

 

[Anthony489]

Hi Dan

I think your engine is the 115PS 1956cc Euro 6 unit. These are less common in the UK. Here are the fault codes for fuel pressure:

P0087 – Fuel rail pressure sensor or rail pressure too low
P0088 – Fuel rail pressure sensor or rail pressure too high
P0089 – Fuel rail pressure regulator performance
P0090 – Fuel rail pressure regulator control circuit
P0091 – Fuel rail pressure regulator circuit low
P0092 – Fuel rail pressure regulator circuit high
P0093 – Fuel system leak detected – large leak
P0094 – Fuel system leak detected – small leak

The code P0094 indicates low fuel pressure. If the fuel pressure drops too low, the ECU will cut out the engine to prevent damage. I agree that the Fuel Pressure Regulator valve could be faulty, it is part of the high pressure fuel pump but can be removed separately. This valve is controlled electrically with a PWM signal at about 1 kHz from the ECU via 2 wires. If do you hear a sound from this it should be a steady medium pitched whistle/buzz.

The clicking noises and the random nature of the problem could indicate a problem with the regulator valve. It is not a very expensive component.

It is also possible that the regulator valve is OK but there is a problem with the electrical connection between the ECU and the valve. I suggest you carefully check the connector pins at the valve and the ECU, and the wiring loom for any corrosion or damage.

 

[AlfA01]

Hi Dan

I think your engine is the 115PS 1956cc Euro 6 unit. These are less common in the UK. Here are the fault codes for fuel pressure:

P0087 – Fuel rail pressure sensor or rail pressure too low
P0088 – Fuel rail pressure sensor or rail pressure too high
P0089 – Fuel rail pressure regulator performance
P0090 – Fuel rail pressure regulator control circuit
P0091 – Fuel rail pressure regulator circuit low
P0092 – Fuel rail pressure regulator circuit high
P0093 – Fuel system leak detected – large leak
P0094 – Fuel system leak detected – small leak

The code P0094 indicates low fuel pressure. If the fuel pressure drops too low, the ECU will cut out the engine to prevent damage. I agree that the Fuel Pressure Regulator valve could be faulty, it is part of the high pressure fuel pump but can be removed separately. This valve is controlled electrically with a PWM signal at about 1 kHz from the ECU via 2 wires. If do you hear a sound from this it should be a steady medium pitched whistle/buzz.

The clicking noises and the random nature of the problem could indicate a problem with the regulator valve. It is not a very expensive component.

It is also possible that the regulator valve is OK but there is a problem with the electrical connection between the ECU and the valve. I suggest you carefully check the connector pins at the valve and the ECU, and the wiring loom for any corrosion or damage.

Thanks for your reply. I've had a busy week and wasn't able to sit down and respond. I took the van to the repair shop again yesterday.

The mechanic seems to think its occurring due to a faulty fuel injector. His theory is that after a long drive the audible noises begin to occur and then the injector slowly starts to freeze in a certain position, which triggers the ECU to shut down the engine to protect it.

 

[AlfA01]

Update from the diesel specialist that tested the injectors yesterday. Two were found to be faulty and another on the verge of being faulty as well. So, it looks like we'll be changing all the injectors.

 

[AlfA01]

So, after a short while of circulating the car the random stumbling and shutting off, plus check engine light has returned. It is more random than before, as I drove today without a problem, but yesterday the engine randomly shut down several times. Also, when I went out to start the car this morning the check engine light was extinguished which is abnormal for the history of the malfunction. Normally the check light remains on.

 

[FeniceFiat]

Hi, I have the same model. Usually with a warm engine, I first start to feel the accelerator pedal harder to press, followed by a loss of power and as I accelerate, the clicks on the high pressure diesel pump begin. Have you solved the problem?

 

[AlfA01]

Hi, I have the same model. Usually with a warm engine, I first start to feel the accelerator pedal harder to press, followed by a loss of power and as I accelerate, the clicks on the high pressure diesel pump begin. Have you solved the problem?

Hello! Yes, my problem seems to have been solved finally. I'm glad you asked, because the notification reminded me I should update this thread.

We eventually changed the diesel injectors, cleaned the diesel pump and changed the high/low pressure fuel switches--all to only continuously have the same problem after a 100 kilometers or so.

If I've translated correctly what the shop told me, we changed the distributor head and cam assembly in the pump. So, my problem was a fuel distribution issue to the injectors.

My engine also seemed to begin the issue when it was hot or had carried a load. After, it began to happen hot and cold as the problem worsened.

Good luck on founding out what is going on with your van.