Hi there,
Based in Scotland, UK
We have a German 1990 2.5 (non-turbo) Diesel Fiat Ducato Camper van which we are pretty happy with, with just one niggling little problem (or "nightmare" to be more honest!) which really spoils it.

We have had an ongoing nightmare regarding timing belts. We've had to have the belt changed due to it jumping (wait for it) _FIVE_ times in the past TWO years.

We bought the vehicle 2nd-hand a few years back, and we had no problems with it at all. When it was pointed out to us that the belt was probably due a change (at 154,449km) we did so. Now we wish we'd left it as it was.

Since then it's been an absolute nightmare. Every few months, the belt goes again. It's gotten to the point that when I call the garage to check up with them on the camper or any of the other family cars, I introduce myself as "we're the owners of the camper you're sick of the sight of", and they know exactly who we are!

We now have a current "mileage" of 156,595 km: Yes, only about 2000km between the original belt change and now ie FIVE belts later... so we're getting on average about 400km per timing belt! Sometimes better, sometimes worse. This has included journeys to & from the south of France & Andorra, but we've had to have garage work &/or recovery there too. When it works, we've no probs, but when this happens, it's very very VERY annoying (& not cheap either!)

Does anyone have any ideas? We are at a loss, as is the mechanic (who even worked on these exact same engines before starting a garage!)

The things that have been changed to see if they helped (& didn't!):
- camshaft pulley
- the complete tensioner assembly (including the small gasket behind the assembly)
- the usual bits'n'pieces when belts need to be changed

When it jumps & we take it to the various garages (we've had to be "rescued" several times) They've all told us the pump timing is "one tooth out", but the tension is correct.

We've checked & quadruple checked that the correct belts are being put on with the correct no of teeth, even going so far as checking with Fiat in Turin with the engine numbers, and them sending us them (Even this one then jumped a short while later)

When this fault appears (out of the blue!), when we try to start the vehicle, it takes a very long time to crank over, & when it finally does start, there's loads of black smoke & very, very little power. When we take it to the garage (if it is able to move under its own steam! - otherwise recovery needed), they then tell invariably us it's the timing belt (& then lots of cursing on our part!). The belts themselves are undamaged, & once the engine is re-timed (even with the original belt), there seems to be no problem... One of the belts lasted a _fortnight_, consisting of driving from the garage home (~15miles) then to the local shops, and home again (another 3 miles). We then wanted to drive somewhere the following week. Lo & behold, the belt had jumped AGAIN!!

WHAT'S GOING ON!!!??
Anyone got any ideas? Please?
Any help would be welcome, as FIAT UK are at a loss too! (I kid you not!)

With thanks,
Mr Schaeffer

Only things I can think of that might make a timing belt jump are incorrect tension of the belt, worn or incorrectly fitted sprockets or tensioners and push or tow starting the vehicle. Push or tow starting is usually OK but it's "best practice" not to push or tow start vehicles fitted with timing belts.

Sorry, probably not much help to you.

Dave.

For my 10pence worth I would say it can safely be assumed it is NOT the timing belt that is the problem here now... Something done by whoever done it has either busted or not been fitted right. Not much help either I know

Don't off hand know the answer to the problem but I've a couple of questions that might help diagnose the issue. When the belt jumps a tooth, is it always the same pulley, (crank, pump or cam) that is out? Does it always jump in the same direction?
Keep well,
Torq

Could it be a keyway on a pulley sheared, so the pulley is turning on the shaft and then jamming again maybe, take all pulleys off and check security / position on shafts ?

(Had this happen once before, took forever to find the fault)

Torq said:

Don't off hand know the answer to the problem but I've a couple of questions that might help diagnose the issue. When the belt jumps a tooth, is it always the same pulley, (crank, pump or cam) that is out? Does it always jump in the same direction?
Keep well,
Torq

Click to expand...

- always the same direction (dunno which, but the garage tells me it's always the same)
- always the pump
- always by one tooth

any ideas?

Are you using all original Fiat parts, and is the repair/ belt change done at an official Fiat workshop?