Tag: Ducato (page 1 of 2)

Ducato Cold Start / Flame Start system explained

The 8140.43 2.8L Diesel engine used in various Fiat Ducato, Peugeot Boxer, Citroen Relay and other vans and MotorHomes uses a fairly unusual cold start system, here we’ll look at how it works so if you need to do any troubleshooting, you know where to start!

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Hymer Headlight Leveler Repair

A common issue on Hymer B-class motorhomes seems to be the headlight height adjustment failing.

The system is hydraulic and consists of a main unit on the back of height adjuster knob in the dash connected to hydraulic actuators on the headlights themselves via tubing. Over time the oil can leak out of the system leaving the headlights in their lowest position.

Fortunately replacement parts are available. Unfortunately it is a sealed system that needs to be replaced as a whole, and is likely to cost over £100 for the parts! Occasionally you might get lucky and find cheaper parts overseas.  I managed to get parts shipped from Germany which saved a decent amount versus buying them in the UK.

This is the system as supplied (as modeled by Muffin) with the dash mounted unit on the top right. You can see one of the headlight actuators at the end of the blue hose on the bottom left (the other headlight unit is hidden behind Muffin’s sleeve!)

First step in replacing this lot is to get the old unit out of the van! If you pull the adjuster knob off on the dashboard you can get to the two fixing screws that hold the adjuster.

The hoses on the adjuster go up underneath the dashboard to the bulkhead where they pass through a grommet into the engine bay. 

Here you can see the grommet and hoses on the bulkhead:-

Next step is to remove the actuators from the back of the headlight units – these just twist to unclip.

You can just about see one of the actuators to the right of the headlight unit here (looking down from the top):-

Once you’ve removed both actuators from the headlights you need to poke the grommet through the bulkhead (from the engine side) and feed the hoses complete with actuators through the hole in the bulkhead to underneath the dashboard. The whole lot can then be pulled out from under the dash.

Fitting the new system is effectively the reverse of removal:

  1. Feed the actuators though to the engine compartment from the dashboard side and seat the grommet in the bulkhead.
  2. Route the hoses to the headlights and clip on the actuators.
  3. Attach the switch unit to the back of the adjuster knob. 


In reality it’s a bit more difficult than that makes it sound as access/visibility under the dash is limited, and access to the headlights requires a bit of a contortionist act.  It’s all do-able with a bit of grunting and swearing.

Here’s Muffin in position feeding the actuators through the hole in the bulkhead:-

Total repair time – a couple of hours including brew breaks……..

Front Suspension Strut / Shock Absorber replacement – Ducato

Front Suspension struts are a very important part of your overall suspension system – and if they wear out you can lose damping performance resulting in an unpleasant, and potentially dangerous, ride.

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Ducato based Motorhome – fixing judder when pulling away from standstill

A nasty judder through the vehicle when pulling away from a stop seems to be a common complaint with Ducato based Motorhomes – read on to understand why this happens and how to sort it…….

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Fuel Filter Replacement

The fuel filter is a service item that is often overlooked, but it very cheap and easy to replace – and a neglected fuel filter can cause all sorts of engine running problems if it becomes blocked from not being replaced on time. Continue reading

What’s that noise?…..ah, that will be the exhaust falling off and dragging along the road…..

Earlier this year we were trundling down a French motorway in our old Hymer B544 motorhome on our way to the mountains for a couple of weeks of snowboarding when suddenly an ominous metallic rattling noise started…. Continue reading

Crusty Sump Replacement

Quick preventative maintenance job this time – The sump on our old Fiat Ducato based Hymer was looking very crusty so I thought I would renew it while I was changing the oil before it rotted through completely and dumped all the engine all at an inopportune moment! Continue reading

Ducato fuel gauge issues – investigation and fix

Common Problem?

It seems to be a common problem with Ducato’s that the fuel gauge either intermittently stops working, or fails completely. There are a couple of common causes for this (note: this is for a 1999 Ducato 2.8idtd. much earlier or later vans are likely to be different):-

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Ducato Oil Pressure Warning Light Fix

Oil Pressure Warning light Problems?

The Oil Pressure Warning light on the dash is designed to let you know if the engine oil pressure drops below a safe level, so you can shut off the engine – hopefully before any irreversible damage is done!

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Fiat Ducato 230 torque settings

Here are some torque settings I have found around the web for the Fiat Ducato 230 with the 2.8td engine – they are not my numbers so I can’t guarantee the accuracy but hopefully they will be useful:-

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