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Technical 2001 Ducato 2.8jtd goes into limp mode on bumpy roads

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Technical 2001 Ducato 2.8jtd goes into limp mode on bumpy roads

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bigjr

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My Hymer motorhome is built on a 2001 Ducato 2.8 jtd chasis. When driving on very bumpy roads the engine goes into "limp mode" and the red spanner light on the instrument panel comes on. After a few seconds of smooth road the engine resumes normal operation and the red light goes out.
I have had the van into 4 Fiat main dealers and specialists, none of whom can fix the problem. They have to use an adaptor to connect the 6 pin diagnostic plug to their 16 pin machines and the error codes given are not specific enough to pin point the problem.
To date the following measures have been taken:
1) wiring connections on the accelerator pedal circuit have been checked
2) new accelerator pedal assembly has been fitted
3) wiring and plugs to the fuel injectors checked for loose connections
4) fuel cut-off valve checked.
5) fuel tank breather vent checked
Fuel blockages do not appear to be the problem as the engine never completly stops.
If "limp mode" is comes on when the accelerator pedal is not being pressed (e.g when approaching a roundabout) no amount of pressure on the accelerator will rev-up the engine - it just comes out of limp mode after a few seconds on its own accord.
One Fiat dealer has suggested that there may be a faultly soldered joint in the ECU but as the fault is intermittant the only way to prove this is to fit a new ECU for approx £500 but even this may not cure the problem!!

I am at my wits end and do not want to spend another £500 on something that may not cure the problem.

Has anyone any suggestions please?
 
bigjr said:
My Hymer motorhome is built on a 2001 Ducato 2.8 jtd chasis. When driving on very bumpy roads the engine goes into "limp mode" and the red spanner light on the instrument panel comes on. After a few seconds of smooth road the engine resumes normal operation and the red light goes out.
I have had the van into 4 Fiat main dealers and specialists, none of whom can fix the problem. They have to use an adaptor to connect the 6 pin diagnostic plug to their 16 pin machines and the error codes given are not specific enough to pin point the problem.
To date the following measures have been taken:
1) wiring connections on the accelerator pedal circuit have been checked
2) new accelerator pedal assembly has been fitted
3) wiring and plugs to the fuel injectors checked for loose connections
4) fuel cut-off valve checked.
5) fuel tank breather vent checked
Fuel blockages do not appear to be the problem as the engine never completly stops.
If "limp mode" is comes on when the accelerator pedal is not being pressed (e.g when approaching a roundabout) no amount of pressure on the accelerator will rev-up the engine - it just comes out of limp mode after a few seconds on its own accord.
One Fiat dealer has suggested that there may be a faultly soldered joint in the ECU but as the fault is intermittant the only way to prove this is to fit a new ECU for approx £500 but even this may not cure the problem!!

I am at my wits end and do not want to spend another £500 on something that may not cure the problem.

Has anyone any suggestions please?
Click to expand...

The codes would be useful, there are lots of places that test ecus, atp are supposed to be good, its just as likely to be a loom issue there are hundreds of wires over the left strut.
http://atpelectronics.co.uk/pages/ecu-testing.html
 
You can usually find a complete ecu, immobiliser, key set on ebay for around 100-150. If the problem persists you can put the set back on ebay and recoup most of your costs.
 
I had similar but it was the injector symbol would come on, no revs either. got it sorted in Belgrade, bad connections on the throttle circuit, I don't know exactly which one but they cleaned them all and now it's perfect. They had come across this problem before and knew where to look straight away. Again it was on bad road surfaces. I would suspect a bad connection somewhere, where to start is the thing.
 
I am having the same problem as digger58 experienced on my Hymer motorhome with the 2.8 jdt engine. Did take it last week to a Fiat main dealer for a diagnostic chickened all they found was faults with the brake and accelerator. They cleaned the brake light contacts and said all was well. Drove the van back but fault returned just as i was nearly home. Had the accelerator control replaced just before I brought the van back in May. Mine also just imported from Germany so have no workshop or owners manual to go on. Will try and find the connections that digger58 mentioned and see how I get on.
 
Hi Dergrowler,

Its now January 2016 and I'm afraid to say that things are still no better re the limp mode on my Ducato.

Did you get any further with your similar problem? My only last resort seems to let the local Fiat main dealer fit a new wiring loom at over £1000 and he admits that even this may not solve the problem.

I feel like driving the vehicle over a cliff. lol.
 
bigjr said:
Hi Dergrowler,

Its now January 2016 and I'm afraid to say that things are still no better re the limp mode on my Ducato.

Did you get any further with your similar problem? My only last resort seems to let the local Fiat main dealer fit a new wiring loom at over £1000 and he admits that even this may not solve the problem.

I feel like driving the vehicle over a cliff. lol.
Click to expand...

Are you 100% certain it's the "Spanner" symbol that is coming on? The symptoms are exactly as mine were, rough road and red "Injector" light would come on, no power, no revs etc, all back to normal then for no reason. I will try to find out exactly where bad connection in the circuit was but that's all it was. The Garage there had come across it many times and recognised it straight away. AFAIK it throws up a fault code for throttle position sensor but 90% of the time it's the connections rather than the unit itself.
 
credit to club motorhome
go into their site
photos there
I cleaned the plugs shown in photo
cleared problem
but hymer has been off the road for winter
so do not know if it was permanent

avee
 
Further to above post
I took motorhome out today On
startup red injector light came up
plus thermometer sign
obviously missing on one injector
gradually picked up power
to 4000 rpm
never cleared properly
presume I will have to repeat cleaning
again as van has been sitting outside in very wet conditions
tomorrows forecast of 80 mph wind and snow looks intering

Avee
 
4th injector loom was too short and tugs on the connector you could splice in a new connector if cleaning it helped most hdi connectors would fit.
 
finally got a reasonable morning
first check leads to injectors
No 4 nearly fell off when checked
sprayed plug again fixed back firmly
nice even tickover again
must not have clipped it properly
last time

Avee
 
Hi all

Sorry have not been on line lately but still have same problem with my Hymer.

Have tried to get a diagnostic check done but nobody seems to be able to connect to the ECU. They have all be using my adaptor lead which I had purchased off eBay. Now I have become suspicious that there my be something a miss with this lead and checked out the pin connections only to find that they are the compleat oppersit to what I have found on the wed.

Have ordered another lead so will wait and see.

digger58. Can I ask where I can find the throttle control board to check these connections as this was replaced befor I purchased the van.

Will keep every one up dated when I can get the correct adaptor lead

Dergrowler
 
Hello
Hello
Does your 2.8jtd have the OBD socket on the dash or the flying leads under the engine lid?
When I first got our motorhome I tried a few code readers to plug into the OBD socket but got rubbish results. In the end bought the 'multieuscan' software and leads from Gendan uk. Really helpful blokes. Read all the codes etc no problem and sorted the engine out in no time.
There's a thread on this forum about 'alfaobd' software with a Bluetooth dongle which should work but haven't tried it but decided after messing about with various code readers to bite the bullet and get the proper kit.
Apparently the Fiat 244 series wasn't obd2 compliant which is why it can be a bit of a problem to get the codes. The 250 series are OK from what I read.
The multieuscan software can do so much more than just reading and clearing codes and well worth it if you're into DIY. It should diagnose if you have a dodgy throttle control pub etc.
Hope you sort it!
 
A Fiat specialist has been able to get an error code from the flying leads to the ECU under the bonnet. The fault seems to lie in the accelerator circuit. The plug going into the throttle potentiometer seems to be damaged and not gripping the pins securely. Tightly tying the plug to the potentiometer with a couple of cable ties has helped but not completely cured the problem.
I cannot source a new plug without buying a whole new section of wiring loom. Does anyone know of a Ducato dismantlers who could supply a secondhand plug with 6" of wires attached (cut from an old wiring loom)? I could then cut off the defective plug and join up the replacement one.
 
bigjr said:
A Fiat specialist has been able to get an error code from the flying leads to the ECU under the bonnet. The fault seems to lie in the accelerator circuit. The plug going into the throttle potentiometer seems to be damaged and not gripping the pins securely. Tightly tying the plug to the potentiometer with a couple of cable ties has helped but not completely cured the problem.
I cannot source a new plug without buying a whole new section of wiring loom. Does anyone know of a Ducato dismantlers who could supply a secondhand plug with 6" of wires attached (cut from an old wiring loom)? I could then cut off the defective plug and join up the replacement one.
Click to expand...

I would probably solder decent multicore wires onto it for fly leads and fill with hot melt glue to provide mechanical support.

One would wonder if its damaged because someone has already been poking at it because of a prior issue.

Is it like this one - its fairly common style for maf, and throttle:
http://www.ebay.co.uk/itm/6-PIN-Con...141894?hash=item1ea1f401c6:g:MJQAAOSw3ydVt6~3
 
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bigjr said:
A Fiat specialist has been able to get an error code from the flying leads to the ECU under the bonnet. The fault seems to lie in the accelerator circuit. The plug going into the throttle potentiometer seems to be damaged and not gripping the pins securely. Tightly tying the plug to the potentiometer with a couple of cable ties has helped but not completely cured the problem.
That sounds much the same as mine was!
Click to expand...
 
I have at long last found a garage who has been able to get the fault codes from the flying lead diagnostic plug under the bonnet. Code P0500 (vehicle speed sensor) and code P0220 (throttle position sensor 2 circuit) both appear at the same time whenever the vehicle goes over a bump suggesting a fault in the connectors or wiring that are common to both circuits. I have no access to a wiring diagram so could anyone pinpoint the precise faulty connector or section of cable that could trigger both fault codes simultanously?
Any help would be appreciated.
 
corcai said:
4th injector loom was too short and tugs on the connector you could splice in a new connector if cleaning it helped most hdi connectors would fit.
Click to expand...

^^^listen to him. Was a recall, longer looms available but most just extend with suitable wire. Fuel rails also let go, though you would know about that!
 
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