Hey everyone,

I'm repairing a Fiat Ducato (2011, 2.3 Diesel) for a friend, but i can't find the problem..
He told me the starter motor got stuck sometimes (shaft doesn't go back). Last time he rode his Ducato the car suddenly stopped working. He transported it on the back of a truck to my workshop.

I replaced the starter with a new BOSCH one. I replaced the burned fuse on the battery (The big Cal5 fuse).

I checked for cables who are cracked, but none has been found..
I thought starter shaft has been stuck again and created loads of current trough the engine, that's why the fuse was blown?

Anyway, i tried to start the car again, no luck and fuse burned again (16euros for a fuse!! at FIAT Dealer.. )

I can't read fault codes as the main battery fuse blows immediately..

Anybody got any idea? I checked the earth from battery and looks good. The earth from engine to chassis looked crap, so i connected a jump-start cable to make better earth. No luck.

Thanks in advance!

A stalled starter motor will blow the CAL5 fuse.


There could be a mechanical fault with the engine.

Is the timing (cambelt) OK?

Can you turn the engine through 2 complete revolutions, by using a socket wrench on the crankshaft pulley bolt?

I'll check the timing this afternoon. But i guess timing is good, van just stopped working while driving.. Timing belt is replaced one year, 10000km ago.

Starter motor is new.. So can't be stalled i guess?

It does not matter whether the starter motor is new or old. If the load is too big (very stiff, or siezed engine), the starter motor will stall.

So. Timing checked, all good. Also engine is not seized.. Somebody any idea??

Hi Crunk

The Cal5 fuse is designed to protect the starter motor cables from getting hot and catching fire if there is a short circuit in the starter motor circuit.

When a starter motor operates normally, it first draws a very high current (maybe over 1000 Amps). As the starter motor speeds up, the current very quickly reduces to under 500 Amps. The high current doesn't last long enough to blow the fuse.

If there is a direct short inside the starter motor or from the positive starter cable to ground, the current can be high enough for long enough to blow the fuse.

If the starter motor is mechanically locked (prevented from turning), the current can also be high enough for long enough to blow the fuse.

Since your fuse blows only when the starter motor is operated, it is not a cable short to ground. Therefore either you have a fault inside the new starter motor (very unlikely) or something mechanical is jamming and stopping the motor from turning.

I suggest you remove the starter motor and check the starter ring gear teeth for damage, you will need to find a way to slowly turn the engine to see all the teeth. Also check that the starter fixing bolts are all OK and the motor is properly aligned and fastened into position.