JCB JS160 can't start

[JoeJR]

I have JCB JS160 with Ecomax 4.5 and 500Hours. it shut down during operation and won't restart. The dealer already tried replacing the lift pump and common rail, but still nothing.
Now they want to replace the injection pump and all four injectors. I checked it out and found out that there are no active codes, but it cranks normally.
Rail pressure is strong during cranking ( 5000psi). JCB claims the rail relief flow is normal due to the electronic relief.
Only cylinder #2 stops smoking when its injector line is capped, and it's the only injector showing return flow.
I'm confused, the rail pressure is good, but why won't it fire? Any tips or insights before we replace the entire injection system?

 

[Earthgoliath]

Okay, so it seems like injector #2 might be leaking inside. Since the fuel rail is holding pressure, it probably isn't a system-wide problem, more like just that one injector. I'd try switching it with another one or testing it before you go replacing a bunch of stuff.

 

[golddigg3r]

Ugh, that sucks big time, especially with only 500 hours on it. Sounds like the dealer is just swapping parts hoping something fixes it instead of figuring out what's really wrong. Smart move doing your own checks before letting them charge you a fortune for random repairs.