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Old 29-01-2012   #1
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2.5TDI cold staring nightmares

Our 1996 fiat ducato 2.5tdi motorhome has real troubles starting when its cold infact it wont start at all most the time when it gets down to 0C and below. anyway i was wondering if the battery is up to the job. it looks like the last owner has changed it at some point and ive managed to get the power rating off it and it says.

CCA SAE 760amps
AH(20h) 88amps

is this strong enough for the job? Ive also read up that it doesnt have glowplugs as such but a flame heater is there anything i can check on this to make sure its working ok, the glowplug light comes on and then starts buzzing but it just wont kick in to life when its cold outside it will work fine other times when the weather is warm.
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Old 30-01-2012   #2
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Re: 2.5TDI cold staring nightmares

I have a 1993 tdi it is a flame heater system. I donīt think mine was working either in the cold. The system works by sensing the temperature, if itīs below 4 I think the flame heater system kicks in. That means it gives current to the flame heater for a few seconds to get it good and hot, then it should squirt some diesel through the heater to warm the air going in to the cylinders- this should give a popping sound like a small explosion in the air intake manifold. The problem with mine was that the relay was porr and not giving enough current to the heater, I did a diy job on the relay, which is next to the battery, and bought a new flame heater- 40 euro I think. But now the van is in warmer climes so not sure if its working ok.

You should check the voltage going to the flame heater when the glow plug light is on. If its ok, it could be you need a new flame heater. There is also a solenoid valve that feeds fuel to the heater, this could also be a problem.
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Old 2 Weeks Ago   #3
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Re: 2.5TDI cold staring nightmares

I have a similar non starting problem on a 2000 2.8tdi direct injection. Is the relay the green box on the bulkhead above the battery please?
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Old 2 Weeks Ago   #4
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Re: 2.5TDI cold staring nightmares

Is it only non starting on really cold days.

Occassionally non starting regardless of the weather or

Is now no longer starting.
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Old 1 Week Ago   #5
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Re: 2.5TDI cold staring nightmares

There is a cold start system on the pump if I remember like a days of old manual choke cable. But the cable gets its power from a thermostat in cylinder head which pulls a lever on pump to richen the mixture.
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Old 1 Week Ago   #6
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Re: 2.5TDI cold staring nightmares

Quote Originally Posted by webmonkeyuk View Post
Our 1996 fiat ducato 2.5tdi motorhome has real troubles starting when its cold infact it wont start at all most the time when it gets down to 0C and below. anyway i was wondering if the battery is up to the job. it looks like the last owner has changed it at some point and ive managed to get the power rating off it and it says.

CCA SAE 760amps
AH(20h) 88amps

is this strong enough for the job? Ive also read up that it doesnt have glowplugs as such but a flame heater is there anything i can check on this to make sure its working ok, the glowplug light comes on and then starts buzzing but it just wont kick in to life when its cold outside it will work fine other times when the weather is warm.
hi. i have the same engine which is actually the IVECO lump and although i have never had a problem starting in cold weather i am aware of the problem. The essential element you have touched on the BATTERY because in very cold weather you are drawing power for three sources all at the same time it is essential that the battery is in fully charged condition and in peak condition and all connections clean and tight,battery terminals-- earth connections -- starter motor and so on otherwise the starter will not turn the engine over at a high enough rate .
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