Well this one has finally hit me, first the basics.
2005 2.8CRD RHD at 130k miles.

It started to get worse at starting, bit of a feather on the accelerator and it usually fires, after the first long cold start it was better. Had replaced glow plugs a while back and confirmed they're working. Battery in good nick too, have tested and topped it regularly. So eliminates the low turnover, glow plug, cold starting usual potentials. At cold start it gives a cloud of greyish smoke. Have also checked, no oil in water or vice versa, nothing suggesting any issues with head, block, etc (Been there in past GV so know what to look for!).

Yesterday it really struggled to start (-1oC outside all day pretty much) as it was starting then immediately dying out. Bit more throttle and eventually it would start, then runs great, no issues.

Until this morning, again cold (-4oC and was cold all night long, so car stood on driveway), really struggled to start and when it started it sounded 'lumpy' almost as though not firing on all cylinders. Cloud of greyish smoke at start too. Drove away and after a few minutes the firing seemed to sort itself out and it sounded happy again.
Until about 5 minutes down the road, went to accelerate away from a roundabout (I'm not a heavy foot so I wasn't booting it) and it really spluttered, again like not on all cylinders (But don't think that was it) and then cut out. Rolled to side of road, tried to start and it turned over a few times until with feathering of throttle it started up.
Without load (Sat in park) I can hit the rev limiter at 2.5k and it sounded fine, no stutters or burbles or anything.
As soon as under load and you take it just above 2.5k it stutters struggles then cuts out, no matter what you do you can't 'regain' it after it does that.

So, sat on the driveway, tickling it to start it'll run, sound fine, I can rev it under no load and it's fine. Leave it to idle for a few minutes and you start to hear it 'seek' so revs drop a little then recover, does that a few times then drops too much and it stalls out.

So things I've done/checked:

* About 1yr ago changed the in-tank fuel filter. Mine is the 2.8CRD with the lift pump in the tank at the rear, changed the screw on filter on it, easy enough and filter wasn't too bad. So my suspicion is it's not that. (This is the Grand Voyager without front filter+primer)
* Low pressure lift pump runs at ignition turn on and primes the system, at least it sounds right
* glow plugs are on/working and pulling current, so not those
* P1130 showing many times on key dance - so it's fuel pressure related (makes sense)
* Pressure relief valve on fuel rail - Tested by disconnecting return pipe, seeing what run-off I get, and it's nothing, zero. So not that.
* Checked connector for fuel pressure sensor (on the common-rail towards the front), connector was ok, voltage ok

So questions on what it could be:

* Crank position sensor
* Fuel heater? (Didn't know anything about this, will check it!)
* Fuel pressure solenoid
* High pressure fuel pump
* Injectors (Though could all have failed/faulty?) - Going to do leak test again to verify.

Anyone any suggestions, I think I'm going to have to get it to a CRD specialist to test the high pressure side out to find out whats going on here.
But anything to help please guys would be appreciated.

 

Not familiar with your Euro diesels...BUT
From some of your descriptions of "feathering throttle to run... Does it have a cable or electronic throttle? IF it has an electronic throttle, however the diesel sys. works may be going bad. Also check for GOOD intake airflow, it may be a diesel..but they still need proper air to run.

 

The only suggestion I can come up with Andy is a very simple one, frozen diesel. In the old days in these temperatures it was common to put a paraffin heater under the tank to keep it liquid.

 

Cheers guys, Rebel59 I see your thinking there but alas it's not electronic throttle or throttle position causing it unfortunately, probably just my use of language there!
Air intake I've not checked so will check that as that's an easy one as MAF might have impact.

AlanC yep that's kinda what I was wondering, especially as there is the small fuel heater in the pump/filter housing in-tank on this one, and with it being cold (And it's cheap supermarket Diesel I've got in it, filled full tank just a couple of days ago). I'm tempted to throw in a diesel additive to up the RON on it and see how it behaves.

 

That was going to be my next suggestion Andy.

 

CHEER's back to you! Please don't tell me that you folk get poor quality fuels over there also!
My main diesel experience is with the VW generations of 78-83 model years...ANCIENT technology now..LOL
Good luck!

 

Everything points to LP 1st Andy. You have the single only 2.8 CRDGV in the whole world with an electric in tank LP pump. My money is on poor supply to the HP side. Best of luck.

 

How's it gone Andy, just been watching this thread so far. Its this struggling on accelerating that indicates something to do with the HP side as Captain says. But saying that I had this cutting out on booting it, AND, as it still happens, cuts power for about 30seconds. Cutting out was remedied with a new Pressure/temp sensor while limp mode thought to be Turbo related, dump valve blocked or actuator not operating. Was recently reading more on this subject of turbo Actuator faults and its quite common on other cars as well. But we're getting into another cosmos here.
As too the pressure rail it does point to pressure related fault. You have checked for it leaking at the overpressure valve. So injector leak-off's would be next.
This leak-off test between injectors is a tricky one that they are to be within a certain percentage. But truth is I read in the Out And About Forum about this Fiat with cutting out prob like yours. I reconned it was Pressure related but watched the recommendations and answers unfold. Pages, live data of engine running, cut-out point on data included. It eventually went to a Fiat dealer who found one injector was SLIGHTLY leaking more than the rest, but within what allowed. So watch this one.
Just had a look at the Dot Co uk forum Andy but I take it you have checked the supply Fuel Filter and Diaphragm for leaks..

 

I hesitated to post on the 12th because I REM your confounded in-tank arrangement.

INJ1 [we all know which one won't come out and is always goosed] see the Vmaxxer recent thread.

Your 702 is really an FR704 and whilst at sub £200 its not gonna do what mine does it certainly can do a whole range of 'live reads' including for example all 4 injectors simultaneously, play with it and find out or just short circuit it and pay a pro to do it properly.

The problem with that particular 702 is that in order to save another £200 to make it a 704 [Asian & European] all the available memory space was used to save the 703/4/5 modules to meaning : if you tell it to save the live read for 30 minutes or whatever you will overwrite & corrupt god knows what.

Best of luck.

 

Only gas models got intank pump , diesels got it in the fuel filter but only 2,5 models placed beside the tank and it's only running before start . 2.8 don't have a electric pump ! chrysler came with an upgrade kit to solve start problems but it's not a in tankpump it's out side.
Manny just mount a universal pump together with glowplug relay and is working great.

If your intank filter is dirty you got a real problem course it only filter bricks and stones all the rest goes to filter in engine bay and block it up quick.

The system if a kinde of high flow so if diesel filter has not been change together with oil change 20000km interval. There is your problem dirty diesel filter and maybe water also.

If you in the past had a bad injector you whole system is contaminated and filter block up quick. usual filter paper is orange or white but after 20000km is look gray or black .