Technical Ducato 250 2.3 2014 don't start

[Pugi8]

Hello!

My FIAT Ducato won't start. I turn the key, but nothing happens—there's no usual sound from the solenoid. The starter motor won't turn even with a different battery. I removed the starter motor and tested it on the bench, and it works fine. It doesn't turn with a new ignition block either. I've ruled out the anti-theft system, but still no luck. What could it be?
Thanks, Gian Paolo."

 

[Reg 65]

Does the padlock light on the dashboard go out when you turn the ignition on?

 

[Pugi8]

Yes.

 

[Pugi8]

Is there any relay between the key lock and the starter?

 

[the green vanper]

Follow the official test procedure, tell me if you're stuck somewhere, so I could paste the following steps.

 

[Communicator]

Is there any relay between the key lock and the starter?

Is the vehicle an automatic?

Do the dash lights illuminate? The charge warning (battery), and oil warning lights should stay on, until engine starts.

 

[Pugi8]

The vehicle is not automatic, the dashboard lights are on without any error signal

 

[Communicator]

The vehicle is not automatic, the dashboard lights are on without any error signal

As not automatic, then unlikely to be a relay in the starter solenoid opertating circuit. Dashboard lights on suggests supply to ignition switch is present at the switch.
I interpret the mention of a new ignition block, as meaning that you have tried changing the ignition switch.
You have then to consider the wiring between the starter solenoid connection and the switch. Typically there is a connector, D104, in perhaps, the RHS rear of the engine bay, which carries both starter solenoid and D+ connection from alternator.
As you have had the starter on the bench, you will be familiar with the solenoid connection at the starter. I would be tempted to make a temporary connection there, and check the voltage when attempting to start.

Attach info has been previously posted by others. The starter solenoid wire is colour coded MV, or brown/black.

 

[Communicator]

Correction, with my apologies. In last sentence of my post #8 above for MV, please read MN.

May I also comment that connector D104 may have more than the 2 ways suggested on the diagram. Fiat diagrams do not show the size of connectors, which is only available when using eLearn, by scrolling down to, and clicking on the appropriate connector, when all is revealed.

 

[Communicator]

CORRECTIONS

1. Typographical error. D104 below should read D004.
2. Having had the opportunity to examine a component location diagram for a later vehicle, it seems that connector D004 may be located near the engine bay fusebox (B001).

Apologies for any confusion.

Correction, with my apologies. In last sentence of my post #8 above for MV, please read MN.

May I also comment that connector D104 may have more than the 2 ways suggested on the diagram. Fiat diagrams do not show the size of connectors, which is only available when using eLearn, by scrolling down to, and clicking on the appropriate connector, when all is revealed.

I do recall reading a report of a corroded connector in that area, but I cannot remember the precise context.

 

[Pugi8]

Unfortunately I am busy and I am unable to continue the search for the fault. Thanks for the clarification

 

[the green vanper]

I do recall reading a report of a corroded connector in that area, but I cannot remember the precise context.

Common problem on the x250's, and less common, but still existing in the x290's. Water ingress into the engine bay through a catastrophic design of the scuttle tray and water evacuation system.

The connectors just behind the left hand side headlight are also problematic, perhaps due to water coming in from the side of the wheel?

 

[Pugi8]

Today I did a test with a light bulb. I connected the positive to the ignition solenoid contact and the negative to ground. Turning the key the bulb comes on, but if I connect the negative to the starter bolt does not turn on. The bolts are securely fastened and the contact with the motor ground is clean. I'm missing something

 

[Communicator]

I am struggling to understand your description of test lamp connections. Could you manage a simple diagram, and either scan, or take photo of diagram.

 

[the green vanper]

I understand that Pugi8 is trying to confirm that the ignition solenoid contact is powered with 12V when he turns the key. But there's no earth on the starter.

I've posted already some troubleshooting guide from eLearn in post #5 above.

 

[Pugi8]

Problem solved! The connector of the braided cable that connects the engine with the body oxidized. The engine was electrically isolated from the ground
Thank you all for your interest

 

[the green vanper]

Great news.

The earth points and cables are a huge problem in the x250.
The earth points tend to rust, not only in the contact point, but also around that point on the body, which makes the resistance much higher.
The cables tend to rot on the inside, too. So it is hard to see.

I'm replacing the original cables with a good quality copper welding wire of the correct diameter.

I'd also double that particular one to another point on the body. I have to do this on my van, too.

Here's a list of the ground points I've posted in another thread:

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