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Old 13-01-2010   #1
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Wont exceed 2500rpm

Hi, I am new to this forum, so am hoping for some help. I have a 2003 2.3 litre JTD Ducato with an Iveco motor. I have recently realised that in top gear the motor is unwilling to exceed 2500rpm. On the flat, autoroute use, it is like I am driving into a strong headwind, and just to look at a hill, the revs drop, and I have to change down. Although it revs a bit more in lower gears, their is not the same power as before.
Trying to pull the skin off a rice pudding springs to mind! Someone has suggested it may be the EGR valve. Does the Iveco motor have one and if so, where is it located.
Or could it be the Mass Airflow Sensor, and if so where is it located.
Any other suggestions welcome.
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Old 13-01-2010   #2
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Re: Wont exceed 2500rpm

Is your yellow engine warning light on the dash , my van (same engine) has had a similar problem OBD said code p0016 and timing syncronisation fault . It has been at main dealer now for 2 weeks and they can't find the problem , everything that has been tested is ok but it just won't go . A factory Fiat tech man is coming to look Thursday . I just hope he finds out what it is , this seems to be happening a lot to other vans . If i find out anything i will let you know.....( mine is 57 plate 20,000 miles 120bhp 2.3)
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Old 13-01-2010   #3
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Re: Wont exceed 2500rpm

Hi Jason,
No, there are no warning lights coming on. Please let me know how you get on. I live in s.w. France, so any help will be gratefully received. Thanks in advance.
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Old 14-01-2010   #4
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Re: Wont exceed 2500rpm

when did you last change the fuel filter ?
could be restricted flow
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Old 14-01-2010   #5
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Re: Wont exceed 2500rpm

Air flow sensor anyone?
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Old 14-01-2010   #6
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Re: Wont exceed 2500rpm

Hi again, yes fuel filter has been changed very recently. Thanks.
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Old 25-01-2010   #7
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Re: Wont exceed 2500rpm

similar problems experienced by myself and "shask" on forum - see 'loss of power black smoke'.
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Old 25-01-2010   #8
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Re: Wont exceed 2500rpm

Worth taking off the EGR for a clean out if it has one, probably will & they are well known for doing similar to your symptoms IMO, could be rear of the engine RHS depending on how the engine is mounted.
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Old 27-01-2010   #9
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Re: Wont exceed 2500rpm

Hi to all who have tried to help me and many thanks for the time you have taken. I have now found the problem and effected a temporary repair, until the replacement part arrives. It was a split turbo hose, from top of the air cooling radiator to the injector nramp. It was masked by, and caused by, a badly mounted alarm siren bracket pressing against the hose, and eventually, after 6 years, causing the split.
The temporary repair is a length of motorcycle inner tube being passed over one end of the tube to cover the split, and held in place by 4 zip ties. The Ducato now pulls like a train, so pulling the skin off a school rice pudding should be no problem. I'm just waiting for the STIG to come and test her.
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