Technical Fiat ducato 2001 2.8d engine swap

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Technical Fiat ducato 2001 2.8d engine swap

Just to add... the van does not have central locking or anything, but the key is coded which lead me to assume it had an ecu... as mentioned before there is no engine management light present... just glow plug light in orange, key code and injector malfunction l;ight (both in red) which go out after ignition on and water in diesel filter light in orange... that's it apart from the usual ignition on lights...
Thanks for your input on this
As has been mentioned, the fact that a vehicle has chipped keys, does not suggets the presence of an ECU.

The ECU on your 8140.63 is for managing the EGR system, not the whole engine. I have read previous references to early ECUs on forum , but I have been unable to find them. I am however puzzled by the presence of an "injector malfunctio light". How would you monitor a mechanical injector? Perhaps it is referring to ECU failure if there is no separate warning.
 
You are unlucky in having the most gutless version of the 2.8 that I can imagine with all that emission stuff on a 80hp version, as I mentioned before I had a 2.5 similar Sofim engine in my first Iveco which was rated at 80hp, it was a 35/80 which meant it was a 3.5 tonne van of 80 hp, but being Iveco it was still capable legally to tow 3.5 tonne at the same time which they did very well, albeit low geared, mind you it had none of the emission stuff of yours.
The 2.8 in my last one the Ducato Maxi van 1997 was a 122hp, I fitted that engine in a boat that originally had a V6 3.75 litre Volvo Penta 150 hp petrol engine and after adjusting the pump and turbo as that model was turbo intercooled I was almost able to match the original engines 30 knots which it did when brand new and 10 gallons of five star petrol whwere as I got 26 knots and averaged 4 gallons to the hour on diesel.
I ran it like that for over four years summer and winter so I would say yes a good reliable engine, with the proviso that it must have regular oil and filter changes and cambelt when due, also never drive hard until fully warmed up.
Yours is a strange one having a MAP sensor, crank sensor, EGR, ECU etc.:)
I am not saying no to a injector pump , but all of mine had well over 100k miles some 250k plus and none ever needed a injector pump or even in my ownerships injectors.
Trouble is now the mechanics are only familiar with ECU controlled much later engines that are nothing like the old stuff.
As you can see in the photos that was all done at a max rpm of 3690, which it could hold for hours once fully warmed up.
I bet that was an enjoyable project to do though... its certainly shifting the boat through..
I enquired about an engine 2.8 idtd.
The trouble is most of them that i found came as a bare engine so not very good for me...I'm keeping an open mind at the moment so will see what happens
 
As has been mentioned, the fact that a vehicle has chipped keys, does not suggets the presence of an ECU.

The ECU on your 8140.63 is for managing the EGR system, not the whole engine. I have read previous references to early ECUs on forum , but I have been unable to find them. I am however puzzled by the presence of an "injector malfunctio light". How would you monitor a mechanical injector? Perhaps it is referring to ECU failure if there is no separate warning.
I will upload a picture of the dash board lights....when i next go up there...this is not my one but the same.. i have just searched online and it states that this is the older version of engine management light....confused even more now :D.... anyway this goes out a couple of seconds after ignition on.....
 

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My 2.8idTD 8140.43
I think it is the same series as the one I put into my boat from the 1997 Ducato Maxi van 2.8 turbo intercooled , I rebuilt the engine and set it up to maximise performance re cam timing and injection pump timing optimising and that was before increasing the fueling and turbo boost incrimentally until I got it to where I wanted, I think if still in the van it would have been pretty good and even at that level it didn't black smoke as the increased boost eliminated it whilst still being economical, all without an ECU or increasing engine revs.;)
 
I will upload a picture of the dash board lights....when i next go up there...this is not my one but the same.. i have just searched online and it states that this is the older version of engine management light....confused even more now :D.... anyway this goes out a couple of seconds after ignition on.....
On my Ivecos they had a similar picture of an injector to indicate an engine immobiliser fault from memory , it was hard to tell back then as no good diagnostics available and Dealers were even worse than Fiat dealers.:(
However if it is just coming on with ignition and then going out before you turn the starter, it may just be running it's correct test sequence and be unrelated to any other problem.
One thing I did with my engine whilst out of vehicle was remove all the basic immobiliser chip side that is under the shroud cover that houses the standard cut off solenoid so I knew in an emergency 6 miles out to sea I could remove the cut off pintle beneath the solenoid and engine would still run to get me home.:)
 
My 2.8idTD 8140.43
As would be expected, except for the injector pipes, that is similar to a 2.8jtd.
I replied to someone with a 2000 2.8 idTD on a FB page with starting issues and everything they've told me leads me to believe it's actually very early JTD.

I guess the rule of thumb I go by now is 'blue clocks and rev counter =JTD'
That does not hold fr my 2006 2.8jtd, which has a black instrument panel.
 
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As has been mentioned, the fact that a vehicle has chipped keys, does not suggets the presence of an ECU.

The ECU on your 8140.63 is for managing the EGR system, not the whole engine. I have read previous references to early ECUs on forum , but I have been unable to find them. I am however puzzled by the presence of an "injector malfunctio light". How would you monitor a mechanical injector? Perhaps it is referring to ECU failure if there is no separate warning.
Possibly as I mentioned on the Ivecos of that era, it was a error message on those that related to the immobiliser, but OPs seems to come on and then go out which hopefully means it is testing a function and then carrying on?
 
I will upload a picture of the dash board lights....when i next go up there...this is not my one but the same.. i have just searched online and it states that this is the older version of engine management light....confused even more now :D.... anyway this goes out a couple of seconds after ignition on.....
Will you post a pic of your engine with the cover taken off if possible. If not then the best photo you can take of your injection pump.
 
Will you post a pic of your engine with the cover taken off if possible. If not then the best photo you can take of your injection pump.
Hello
Yes of course, il be taking the cover off on Saturday anyway and will take some of the pimp etc.
Thanks
 
Hi,
Would you know whether a 2.5tdi from a ducato (1994) I believe go straight in to my one,, and do you think it would be much of an improvement in your opinion
 
Hi,
Would you know whether a 2.5tdi from a ducato (1994) I believe go straight in to my one,, and do you think it would be much of an improvement in your opinion
It is basically the same, but that sounds quite an old unit , have you heard it running?
Also to get any power it would need the intercooler and turbo plus manifold etc.
Personally I would hold out for a good 2.8 TDi engine and use the the turbo and intercooler that comes with it.
The earlier 2.5s were indirect injection so a less efficient design.
 
It is basically the same, but that sounds quite an old unit , have you heard it running?
Also to get any power it would need the intercooler and turbo plus manifold etc.
Personally I would hold out for a good 2.8 TDi engine and use the the turbo and intercooler that comes with it.
The earlier 2.5s were indirect injection so a less efficient design.
I have heard it running on video, sounds ok, it is still bolted to the sub frame, and a bonus is that it includes everything with it,
I didn't see any intercooler though to be honest, definitely has the turbo, the seller said it comes with all ancillaries,
Including the gearbox but 5th gear was a little finicky...
It is a good price but I don't want to go through all of the work with little improvement..
Il take what you say on board and maybe keep looking for now. It is actually 1996 not 1994
Thanks
 
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I have heard it running on video, sounds ok, it is still bolted to the sub frame, and a bonus is that it includes everything with it,
I didn't see any intercooler though to be honest, definitely has the turbo, the seller said it comes with all ancillaries,
Including the gearbox but 5th gear was a little finicky...
It is a good price but I don't want to go through all of the work with little improvement..
Il take what you say on board and maybe keep looking for now. It is actually 1996 not 1994
Thanks
Can you check the actual Serial Number and compare with yours, if you then put Sofim Engine on Wikipedia it should explain the main differences between yours and his, if any. Generally the odder early one I think from memory was an 8144 and yours starts 8140.**
If engine is on it's subframe and rest of vehicle not there, the intercooler and correct hoses may have been left on vehicle, this will be an added expense.
When you say you heard it running in a video was this with coolant/radiator etc. or only for a few minutes/seconds as a very rough guide?
If you do go ahead try and get the exhaust front pipe as well as everything else you can find.
Obviosly keep your old parts/engine for spares.
Good luck with it , but your choice, your decision.;)
 
Can you check the actual Serial Number and compare with yours, if you then put Sofim Engine on Wikipedia it should explain the main differences between yours and his, if any. Generally the odder early one I think from memory was an 8144 and yours starts 8140.**
If engine is on it's subframe and rest of vehicle not there, the intercooler and correct hoses may have been left on vehicle, this will be an added expense.
When you say you heard it running in a video was this with coolant/radiator etc. or only for a few minutes/seconds as a very rough guide?
If you do go ahead try and get the exhaust front pipe as well as everything else you can find.
Obviosly keep your old parts/engine for spares.
Good luck with it , but your choice, your decision.;)
Yes it was in the van when i heard it, the rest of the vehicle is still there as the person that's selling it said he also has the front panels etc,
I will follow your advice though and ask for the number from the engine and check 1st,
Will let you know, thanks
 
Done a. Number plate search, I believe this is the engine, will double check 1st though
ENGINE Fiat Ducato Estate (Wagon) 2.5 TDI 1996.
TORQUE 245
NUMBER OF GEARS 5
INSTALLATION POSITION / ENGINE TYPE Front engine / Series
NUMBER OF CYLINDERS 4
FUEL INJECTION TYPE Direct injection
SUPERCHARGING Turbo
NUMBER OF VALVES 2
ENGINE SIZE / DISPLACEMENT (CCM) 2500
POWER / TORQUE 85 kW (115 HP) / 245 Nm
POWER (KW) 85
POWER (HP) 115
ENGINE SIZE / DISPLACEMENT (CCM) 2500 ccm
MAXIMUM POWER AT RPM. 3800 RPM
MAXIMUM TORQUE AT RPM. 2000 RPM
 
View attachment 472084it is 8140.47.. and it has the turbo/intercooler with it... is this the same as you fitted in the boat?
No mine was the 2.8 rated at 122hp. :-
8140.43
2799​
118 (87)/3600
122 (90)/3600​
270 N⋅m (199 lb⋅ft)/1800
285 N⋅m (210 lb⋅ft)/1800​
R4, DI, turbocharged, intercooled​
OHC/8​

This is yours according to wikipedia:-
8140.47
2499​
116 PS (85 kW)/3800​
245 N⋅m (181 lb⋅ft)/2000​
R4, DI, turbocharged, intercooled
OHC/8​
 
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