Ducato X250 throttle body change

[Canalsman]

I have had ongoing issues with my Ducato Multijet 160 chassis cab engine.

I limped back from the south of France with persistent, but intermittent, 'hunting' which feels like a misfire but is actually the throttle opening and closing in an uncontrolled fashion.

Due to poor design water can drop onto the throttle body, which can then suffer water ingress, having run from the scuttle, then down the engine cover. This cover has now been extended to protect the throttle body.

I ordered a replacement throttle body from an online supplier in Germany, much cheaper than buying in the UK, and had this fitted by my garage.

My Ducato is 2007 and left the factory with a Wahler throttle body.

The replacement throttle body is made by Pierburg and misbehaved on fitment with the Engine Management Light staying lit permanently and the engine running in 'limp' mode.

This website explains the issue:

Adapter cable for regulating throttles * Technipedia * Motorservice

I purchased the adapter cable, not cheap at £70 but cheaper on eBay, and once fitted the problem was solved.

So beware in the event that the throttle body requires replacement.

 

[yeoblade]

Yes, I had to replace mine last year too.fortunitly I was only 20 miles away from home and just manged to limp home. X250 chassis.
Water damage from the crap windscreen scuttle design, even with the improved engine cover (umbrella) water got it eventually.
I bought the parts from ebay seller coastal-motorhomes. They have a good selection of spares for the X250
Total cost for the new body and converter lead about £225. and a good day to strip the front off the van to get to it, with only one screw seized in, lucky not one of the ones tapped into the cylinder head.
Just had mine MOT'd and I've got the next X250 fault - Handbrake! just passed but I'll need to carry out the maintenance adjustments.
The good thing is Ducatos are pretty predictable, they all go wrong the same so there is plenty of info on all the faults

I stripped down the old part and you could see the water damage corrosion causing the actuator to stick/fail.

The water still drips in, over winter I put a tarp over the front to stop it.

 

[Canalsman]

Incidentally my mechanic suggested replacing the glow plugs whilst it was all stripped down.

As he pointed out if I left it till later all the same disassembly would be needed again, so it made sense.

I would recommend you extend the engine cover. A piece of thin plastic has been bolted onto the underside of the existing cover and this will ensure that water will not get to the throttle body.

 

[Deleted member 35703]

Rather than just put a like
That is a very good informative thread thanks

 

[yeoblade]

Incidentally my mechanic suggested replacing the glow plugs whilst it was all stripped down.

As he pointed out if I left it till later all the same disassembly would be needed again, so it made sense.

I would recommend you extend the engine cover. A piece of thin plastic has been bolted onto the underside of the existing cover and this will ensure that water will not get to the throttle body.

2.3L Engine. I think the glow plugs are easily accessible from the top though they and injectors may be covered in rust due to the water running in and pooling in the top of the engine :mad2:

:idea-007:Great idea will add an extra drip shield to the existing non effective cover.

 

[Canalsman]

An update ...

I've been driving it a bit now and all is well.

Better still the engine performance is markedly better with improved throttle response and it just feels more lively.

In the four years that I've owned the 'van the fuel consumption has increased somewhat but I didn't have anything to pin that on. Maybe it will now improve. I'll report back in due course.

 

[yeoblade]

Is yours the 3litre engine Chris? Any pictures of your cover mod?
I looked to increase the engine cover size on mine, 2.3l , but it looks quite impossible to do to cover the throttle body.
However I have tried to seal the join in the windscreen scuttle (It is originally a foam 'seal' that leaks !! doh) and I have drilled and routed another drain pipe to drain away most of the water, but not all. You can still see it dripping in slowly from the scuttle join

Keeping all the drain pipes clear is important. When I got my van I noticed that the drivers side wiper arm, very bottom part, has corroded badly and the black paint had come away as the ally had started powdering, this drain hole was completely blocked. Look around a dealers on a rainy day over half of the X250s had blocked drain away pipes by the wiper arm !

 

[Canalsman]

Mine is the 3 litre Iveco engine so extending the cover is very easy, remembering of course to attach the extension under the existing cover.

I agree about the drain - must check mine tomorrow!

I don't think it's possible to seal the scuttle moulding 100%. Polyurethane sealant is the product most likely to work but the overlap at the join is quite narrow.

 

[yeoblade]

I used guttering sealant on mine.

 

[Fazerloz]

I would also check the windscreen wiper bushes. Mine seized and broke, tearing the aluminium bush off its crimped stub end coming up the M1 rendering the wipers useless. Luckily I was able to repair and didn't have to buy new. But a pain in the arse to remove.

Repaired Bush.

 

[Fazerloz]

Just found a pic of the damage done when it seized.

 

[Bobster]

I have had ongoing issues with my Ducato Multijet 160 chassis cab engine.

I limped back from the south of France with persistent, but intermittent, 'hunting' which feels like a misfire but is actually the throttle opening and closing in an uncontrolled fashion.

Due to poor design water can drop onto the throttle body, which can then suffer water ingress, having run from the scuttle, then down the engine cover. This cover has now been extended to protect the throttle body.

I ordered a replacement throttle body from an online supplier in Germany, much cheaper than buying in the UK, and had this fitted by my garage.

My Ducato is 2007 and left the factory with a Wahler throttle body.

The replacement throttle body is made by Pierburg and misbehaved on fitment with the Engine Management Light staying lit permanently and the engine running in 'limp' mode.

This website explains the issue:

Adapter cable for regulating throttles * Technipedia * Motorservice

I purchased the adapter cable, not cheap at £70 but cheaper on eBay, and once fitted the problem was solved.

So beware in the event that the throttle body requires replacement.

H

Just found a pic of the damage done when it seized.

View attachment 70549

Hi canalsman new member here,had exactly the same problem as you with the throttle body which I found out after getting a fault code PO638.i am not a mechanic but attempted the job on my 2008 Fiat ducato 3 litre.removed grill and front faring 20 mins no problems with rusty screws or bolts.removed throttle body found it to be completely rusted up inside,purchased new one,eBay £94.installed the part still had engine management light on,read your thread about adapter cable,bought one eBay £24 fitted that, problem solved after 4 turns of the ignition.thankyou.

 

[Canalsman]

H

Hi canalsman new member here,had exactly the same problem as you with the throttle body which I found out after getting a fault code PO638.i am not a mechanic but attempted the job on my 2008 Fiat ducato 3 litre.removed grill and front faring 20 mins no problems with rusty screws or bolts.removed throttle body found it to be completely rusted up inside,purchased new one,eBay £94.installed the part still had engine management light on,read your thread about adapter cable,bought one eBay £24 fitted that, problem solved after 4 turns of the ignition.thankyou.

You will probably find that the 'van drives much better with the revised throttle body. It made a big difference for me.