A little advice.

Take out your passenger headlight,
Unbolt the ECU plastic cover,

One of the main Wiring looms to the ECU is cable tied from factory to the metal ECU mount,

Cut this cable tie

Check wiring hasn't worn through from chaffing against metal bracket

I've just had a new turbo fitted, to find the wiring had worn through over time, most of the wiring was green and corroded, auto electrician had to make new loom up for certain wires.

Still at least I've a new turbo and know she's good for another 360,000 miles (I wish)

Worth checking if you have other faults too

Hi. Dont suppose you know if one of those wires relates to the throttle? I have an intermittent fault to ground code related to the throttle, no effect on performance. . . Yet.

Most throttle issues are the valve, again water ingress, or clogged up so bad they don't move,
But anything is possible

My faults were turbo pressure sensor, P2563

Turbo specialists checked, dealers checked all diagnosed turbo, but had read on here and word of mouth about cases of turbos being replaced and fault still there, then wiring fault found

Even told turbo/diesel inj specialist who did work to check, they came back as deffo turbo, so they reconditioned my blower, then had to get electrician in to solve, make up a new replacement loom,

So it could be, but I'd also be checking throttle valve, 2.3 I believe is located passenger side of engine, 3.0 is drivers front corner of engine

Many Thanks rolopolo for this thread. I took my headlight out this morning and found the loom going to the ECU was chafing on a smooth round metal tube where I wouldn't have expected it. I don't know if this is the same as yours rolopolo. - I will try to attach pics.
The paint had worn off the tube, so corrosion had made it like sandpaper. It had not only worn through the binding tape of the loom but the insulation as well!!
If it had been left to go any further it would no doubt have done some funny things with the ECU
I have bound it with tape (red for clarity) and wrapped it in rubber hose to stop further chafing.

Peter, exactly the same as mine, mine you could see just a tiny wear on the insulation on a wire, but corrosion had worked its way all along

Thanks Again Rolopolo. I've done 58,000 miles (2008 Citroen Relay 2.2) and would not have imagined the wiring loom would be moving enough to chafe through to the core of the wire on this round steel tube, even with the headlight out you wouldn't notice it until you lifted the loom and looked underneath. Looking at the wire it couldn't have gone much longer without problems. So I am very glad to stop it now.
Had a look round and couldn't see chafing anywhere else so its a relief to hear its in the same place as yours because I didn't find any cable tie (which you mentioned cutting).

The fiat layout is slightly different but exactly same issue,

You will find if yours has worn the outer wire plastic through, it will be corroded, maybe not the small area you can see, as that's been rubbed clean, but peeling back the outer cable will show corrosion, mines not quite 4 yrs old, ok done mileage, but all the water that runs down the back of headlights, through the windscreen scuttle, etc will have got in,
Just wrapping up with tape won't stop any damage that's already done. Just be aware that's all,

rolopolo said:

The fiat layout is slightly different but exactly same issue,

You will find if yours has worn the outer wire plastic through, it will be corroded, maybe not the small area you can see, as that's been rubbed clean, but peeling back the outer cable will show corrosion, mines not quite 4 yrs old, ok done mileage, but all the water that runs down the back of headlights, through the windscreen scuttle, etc will have got in,
Just wrapping up with tape won't stop any damage that's already done. Just be aware that's all,

Click to expand...

Yeah the conductor looked a bit green so I wondered about that. But everything seems to be working fine at the moment (surprising because it was touching the metal tube where it could have shorted) and I wrapped the loom up well whilst it was dry so am hoping for the best. I thought of splicing new wires in (soldering or choc block connectors) but would be awkward to keep the connections dry. I will keep it in mind if I have any faults developing later.

i think that's where my wiring went, 15 plate 3litre Boxer 96,000 miles. Mine the engine kept momentary cutting out and saying service due & at one point the cruise packed up. Think it was 2 wires gone

Guess yours was covered by warranty Vito115?

I would check they haven't cable tied loom back to bracket before it goes again

i will check tomorrow. It was done under warranty, they were going to put a loom in but it was back order and they (Peugeot) were paying for a Tran5h1t Luton @ £90 per day suddenly decided to repair the loom !

I'm very grateful for these 'stitch in time' tips so have checked my van.

I'm happy to note that my loom has been fitted to be well clear of the tube with no cable tie in evidence (difficult to see from photo but there is a couple of cms clearance)

Don't know if I was just lucky or whether the fit had been amended by then (probably a 2009 build chassis) or whether there was a different loom for the 2.3 engines.

Thanks for the photo Crossingkeeper. Your loom has been fitted with a protective sleeve, mine hasn't - just wrapped round with tape which has worn through at the top left of my first picture - I was holding it out of the way to show the rusty abrasive patch on the tube, which was completely hidden when the loom was in position.

Looked under the bonnet of my van and didn't recognize any of these pictures. The loom is wrapped in a harmonica sleeve with rubber grommets in the metal supports, no rubbing of chafing anywhere. My vehicle is of course the continental version.

So I guess Fiat is punishing you for driving on the left side of the road....

CDK said:

Looked under the bonnet of my van and didn't recognize any of these pictures. .

Click to expand...

You can't see it without removing the headlight.

And the ECU cover needs removing , RHD Iveco 2.3 & 3.0 engines

You can see my new loom the electrician made up, the cover that covers loom and ECU needs removing, to gain access to the area where the loom chaff's against bracket, (headlamp requires removing to gain access the ECU cover

Found orig photos from a few month ago, when I first found my loom, hardly any visible damage to the wires, but they were bad as the water had worked its way in

Mine looks to be worse than the photos above. As in all the others the problem seems to be from the paint on the black steel tube rubbing off easily so rust makes the surface rough as sandpaper.. There is no sign of rust where the loom touches other painted surfaces which are part of the main (galvanised I think?) bodyshell. My loom was wrapped with only thin plastic tape, not the felt stuff in other photos. 2 wires were damaged, and appeared to be just about worn down to the copper core. But the core was intact and the wires were dry because the van had been standing for a week without rain. So I put a bit of insulation tape around the partially exposed wires, before binding it up with more tape and covering it with rubber hose for further protection.

Hi

I have an 07 X250-130 Multijet in my Motor-home, Just had a brief look with the Endoscope and can see no fretting at this time. I will have to make time to have the headlight out and make shure.

Pete