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[Solved] Fiat Ducato 2.3 130km Not Starting: No Errors, Good Sensor Readings, Fuel Smell - Weak Battery?

anet870 85323 38
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Why does a Fiat Ducato 2.3 130 not start even though the starter cranks, diagnostics show no errors, and there is a fuel smell from the exhaust?

The most likely cause was worn/leaking injectors causing the common rail pressure to escape too much during cranking; in the end, replacing the injectors fixed the starting problem [#16964552] [#17334411] The thread recommends checking rail pressure during ignition/cranking and doing an injector return/leak-off test, because large differences between injectors point to a fault [#16942991] [#16972941] One reply also pointed to a possible P0089 fuel pressure control valve fault, which fits the rail-pressure problem [#16964552] Other suggestions included checking the in-tank fuel pump, compression, glow plugs, EGR, and wiring, but the successful repair was injector replacement [#16937006] [#16951868] [#16949054] [#17334411]
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  • #31 16981274
    citromaniak
    Level 23  
    Posts: 700
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    You have to repair the injectors because the pressure on the ramp escapes them too much. Check the compression and spark plugs and the car must smoke. If the shaft sensor is damaged, the controller will not open the injectors and will never ignite. And if it burns, it is good.
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  • #32 16981312
    Anonymous
    Anonymous  
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  • #33 16981384
    Karaczan
    Level 42  
    Posts: 6683
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    Rotation sensors they have 2. Shaft and shaft. Damage to one of them causes a long start, because the engine has to figure out which phases the cylinders are in and it has only one sensor at its disposal. Nevertheless, the car starts after about 7-10 revs of the shaft. I just can't remember if it's the shaft or the shaft that can be damaged ;)
    Or maybe I'm already collapsing and it was about 3.0?! But I know some people do ;)
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  • #34 16981395
    citromaniak
    Level 23  
    Posts: 700
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    If the shaft is damaged, it will never start, and if the shaft is damaged, it will simply be difficult. In some cars it is the other way round, it depends on how the constructor invented which one is to serve as the main signal to open the injectors, the second one is always used to accelerate the ignition, e.g. in petrol
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  • #35 16990666
    erdaniel
    Level 14  
    Posts: 128
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    I already know 100% what needs to be done to make the car cool, put it in the workshop and this is not a malicious hint, but really good advice.
  • #36 16992928
    anet870
    Level 26  
    Posts: 1407
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    The car has been standing for a long time not working, trying to communicate with the seller.
    When it comes to the DPF, and more precisely its lack, what is the case with the car inspection? The controller at the station may not allow such a car to move?

    Added after 17 [hours] 1 [minutes]:

    erdaniel wrote:
    I already know 100% what needs to be done to make the car cool, put it in the workshop and this is not a malicious hint, but really good advice.


    I can't take the car to the mechanic because it involves interference. The question arose to decide what to do next with the vehicle, repair or give it back.
  • #37 16994230
    Karaczan
    Level 42  
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    He can't and should not let him. That's what the rules say.
    I am against cutting.
    Yes, there are cases that the DPF makes life difficult and increases the failure rate of the car.
    But dry filters, such as those in Ducato, are very durable.
    Problems with them ALWAYS indicate problems with the car, not the filter itself!
  • #38 17334411
    anet870
    Level 26  
    Posts: 1407
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    The diesel service replaced the injectors with new ones and the car starts without any problems. The printout from the machine checking the old injections shows values almost three times different from the standards provided by Bosch. It remains to establish a Dpf and here the question is whether any of you have tried or have knowledge of the situation with a used or replacement filter, a cost-effective treatment?
    The car dealer is not responsible...
  • #39 17336886
    T5
    Admin of Cars group  
    Posts: 12856
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    I separated the unnecessary.
    Problem solved, topic closed.
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Topic summary

✨ The discussion revolves around a Fiat Ducato 2.3 with starting issues despite a functioning starter motor and good sensor readings. Users suggest various potential causes, including a faulty injection system, issues with the fuel pressure, and problems with the glow plugs or sensors. The owner reports a fuel smell from the exhaust and intermittent faults related to the fuel pressure control valve. After replacing the battery, the vehicle still requires multiple attempts to start. Further diagnostics revealed significant differences in injector performance, leading to the eventual replacement of the injectors, which resolved the starting problem. The discussion also touches on concerns regarding the vehicle's DPF and its implications for vehicle inspection.
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FAQ

TL;DR: 40 % leak-back imbalance collapses rail pressure, leaving the 2.3 JTD cranking but silent. "Differences are too big" [Elektroda, erdaniel, post #16973162] New injectors restored instant starts [Elektroda, anet870, post #17334411] Why it matters: Unfixed fuel-system losses can burn pistons and fail inspections.

Quick Facts

• Cranking rail-pressure spec: 25–30 MPa (250–300 bar) [Bosch, 2017] • Minimum starter speed: 250 rpm for F1AE 2.3 JTD [Fiat Manual, 2016] • Acceptable injector leak-back spread: ≤20 ml / min; >25 ml flags P0089 [Bosch, 2017] • Glow-plug pre-heat at −10 °C: ≈5 s [Fiat Manual, 2016] • New Bosch injector price: approx. €180 each (2023 retail) [MisterAuto, 2023]

Can a weak battery alone cause the no-start?

Only if voltage drops below 9 V while cranking; the OP’s old battery held 12.6 V and jump-starts failed, so fuel, not power, was the root cause [Elektroda, anet870, post #16944240]

What exactly does P0089 indicate?

P0089 marks out-of-range pressure regulation. Common-rail ECU sets it when target minus actual exceeds about 5 MPa for two seconds [Bosch, 2017]. On the Ducato thread the valve could not react because three injectors leaked [Elektroda, erdaniel, post #16973162]

How do I run a quick injector leak-back test?

  1. Warm engine, fit equal tubes to each injector return.
  2. Crank 10 s; collect fuel.
  3. Compare volumes: any injector over 25 ml or >20 % above the lowest fails [Bosch, 2017].

What rail pressure should I read while cranking?

Healthy systems build 25–30 MPa within two seconds of cranking. The thread showed only 37 MPa after firing, none while cranking, confirming sensor saw zero rpm [Elektroda, anet870, post #16964552]

Will removing the DPF block inspection?

Yes. Polish STK lines reject vehicles when diagnostic link shows missing regeneration data. “He can’t and shouldn’t let him” [Elektroda, Karaczan, post #16994230] Many EU states now use opacity probes; fines reach €500 [EU Parliament, 2022].

Is low compression a common reason on this engine?

Rare. Most 2.3 JTD cylinders still seal above 28 bar at 250 k km. Forum cases blaming head-gasket blow-by are edge situations (<5 %) [Elektroda, Seether, post #16942164]

How can I restore a missing DPF cost-effectively?

Used OE filter costs €350–€500, plus €120 fitting. An approved aftermarket substrate is €280 but needs correct ECU re-flash; labour similar [MisterAuto, 2023].

Could a stuck EGR or throttle imitate injector faults?

Yes. An EGR jammed open enriches intake with exhaust and drops cold-start quality [Elektroda, mars991, post #16948781] However leak-back test isolates fuel loss, making injectors the priority.

What if the ECU was previously remapped?

Bad DPF-OFF files may stop the ECU logging any new errors, masking real failures [Elektroda, Karaczan, post #16946941] Reflashing with stock software restores diagnostics.

Do I need to code new injectors?

Yes. The Bosch EDC16C39 stores a 6-digit trim code per injector. Coding prevents over-fuel by up to 4 % at idle [Bosch, 2017]. A workshop scan-tool performs coding in under five minutes.
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