Own a 2002-2008 Fiat Ducato (244) with the 2.3 JTD or 2.8 JTD engine? These are five problems owners ask about again and again on Fiat and motorhome forums, with the fixes that worked for them.
Engine
Why does my Ducato 2.8 JTD whistle or hiss under boost?
Owners point to a boost leak first. Two 64 mm hoses run from the intercooler: the lower one to the turbo and the upper one to the inlet manifold. Check every clamp and look for splits in both hoses. The turbo sits at the back of the engine, so you need to raise the van to reach it safely.
When should I change the timing belt on the 2.3 JTD?
Owners go by time as well as mileage. Most motorhomes cover few miles, so the belt usually ages out first, at about 4-5 years. Check the interval for your exact engine before you book the job.
Why is my 2.8 JTD slow to start?
One owner fixed slow starting on an early 2.8 JTD by setting the camshaft sensor gap. On some vans the sensor sat too low. The fix was to raise its bracket with thin washers to get the correct clearance from the cambelt pulley. After that, the engine started on the first turn of the key.
Gearbox
How do I make a stiff gear change smoother?
One owner greased the gear selector casting on the horizontal shaft at the back of the gearbox. It is under a black plastic cover, held by a 13 mm nut, and you can slide the casting along the shaft to grease it. He also greased the cable pivots, and gear selection became smoother.
How much gearbox oil does the 2.8 JTD take?
A forum member says the first figure was 2 litres, later raised to 2.7 litres to give the 5th gear set better lubrication. The fill points on top of the gearbox are hard to reach, so he fills through the speedo sensor hole at the back, from underneath. Don’t drop the bolt or washer into the hole.
Get the repair software
Step-by-step repair procedures for the 2.0, 2.3 and 2.8 engines are in the Fiat Ducato 2.0 2.3 2.8 Repair Software (2002-2008). More: Fiat Ducato manuals.