Technical Starting problem: no headlights, no panel lights, starter works, but engine doesn't

Currently reading:
Technical Starting problem: no headlights, no panel lights, starter works, but engine doesn't

whiterabbit

New member
Joined
Apr 29, 2013
Messages
7
Points
1
Maybe some experienced Ducato 1990 techs can help me to figure this out:

When I turn the key to 'on', there is missing only
- the headlights
- the cockpit panel lights

All other visible electrical appliances seem to work fine.

When I turn the key to 'start', the starter motor works allright, but the engine doesn't come on. (It sounds like the engine does not get fuel.)

Fuel tank is full, battery as well. All fuses for the headlights in the glove compartment are fine, but no voltage there.

I seems to me as there could be a common cause, like e.g. a failure of a common ground or plus line for the failing devices mentioned above plus, if there is maybe, a fuel stop valve (devices that are switched on simultaneously with the key in 'on'-position.

Power after the key switch is good, though. I figure the problem might be on the ground side of the key switch but on the plus side of the headlight switch under the steering wheel, which seems to have no power. (I haven't assured this yet, but as the motor does not come on, I think about a common cause).

I lack an electrical schema, and I was reluctant to disassemble the front interior without a further hint; so I was not yet able to track all the lines in question...

Any idea, somebody?

Are there in line fuses to check or is there a connector that could come off or corrode?

Any help will be very much appreciated.
 
Last edited:
I called 7 dedicated Fiat workshops.

Each company was asked the same questions.

Each partner in conversation was given the exact model, esp. the year of manufacture, which is 1992.

1. Is there someone familiar with the model?
2. Can I please talk to an expert?

Being put through to an 'expert':
3. After explanation of all the symptoms, can you figure a solution?

If there was no solution beyond bringing the vehicle in:

4. How would you find out what's wrong?
(Here I allways pointed to the coincidence of engine and head lights failure repeatedly)
5. Is documentation about the wiring and deployment of compponents available?


Result:

All companies told me that there is no documentation on the model available at all. (That means, if there is no veteran expert on that model, someone would learn on my expense, right?)

One company told me they would have me called back by a chief tech, but they didn't.

One company's secretary would not put me through to a technician, but would answer by herself.
After she diagnosed that I must have used a non-transponder-key and learning that my model does not yet have a tranponder key, she suspected that the engine control unit must be at fault. I should come in to plug the diagnosis device. I told her that I had thought about the option, but that I would have had problems finding the plug. So she told me again to bring it in. ROFL

One company's head mechanic told me that they where not in Fiat business at that time, so there was nobody who would know about the model. As no documeńtation was available, they could not tell nor take an order for repair. (Thanks for the honesty!)

Four company's technicians told me, that the engine failure and the headlights failure must have different causes, which could only be found by systematic testing. All technicians ignored the problem of the failing headlights in consequence and focused on the engine.

One technician told me, I should first find out if there is really no fuel supply to the engine. To find that out, I should remove the air intake and put in some starter aerosole or break cleaner. If the engine should run a few turns then, the fuel supply must be interrupted. (I didn't talk to him more because to my knowledge, starter aerosole can inflict sudden death to a diesel engine.)

Three technicians told me to find out about the fuel supply first.

All except one technician told me either that there is no fuel stop valve in that model or that it's possible failure must have a different cause than the failure of the head lights. One of them told me, that there was no electrical failure, because this model didn't have much electrical failures; this model was 'all mechanical'.

One technician told me the fuel stop was mounted on the fuel pump. First thing to do would be to diagnose the engine failure, eventually tracing the ground lines, which would be bothersome. The headlights problem could be caused by the ignition lock, but this should be checked after the engine problem.

This thread now has 45 views and no replys except from myself.
 
Hi,
My reply won't be that helpful as it's just that you haven't stated whether your van is diesel or petrol ;)

I owned a 1989 Talbot which is basically the same van, however this was petrol engined with a distributor and carburettor so I could base any fault finding on my previous experience with cars, however even if yours is the diesel version it is a basic mechanical fuel injection pump with, as you say, an electrical solenoid to control the fuel shut-off.

A difficult problem to diagnose over the net, however if you have an immobiliser fitted on your van I would look at that, if not you need a good auto-electrician (if you can't sort electrics out yourself) as plug-in diagnostic systems won't be a great deal of use for your van.
 
So you phoned around dealers questioning their expertise and integrity, asking them to tell you how to fix it for free and are then roll on the floor laughing that they wanted you to actually bring it in for repair. You do realise they are running a business not a charity.

It doesn't get much simpler than a 1990 diesel ducato they're not going to need a wiring diagram or documentation. Even if they had documentation it would take longer to find/look at the wiring diagram than trace the wires.

Ignition switch is likely suspect, check if theres 12v on the stop solenoid
 
Hi moodrater,

you are quite busy on this forum, aren't you? Thanks for your distinct answer.
Thanks to CrossingKeeper as well.

Well, I think this answer is that of a true Fiat professional; I, as an amateur in screwing cars, fed up being ripped of by dumb-as-bread or lying bastards of car mechanics, was suspecting, that the symptoms that I mentioned would take an educated professional in a straight line to the solution.

I, myself, had to spend hours with a multitester to check out all the wires, that was deliberately undocumented by Fiat (What would be a no-go in the US, where automobile manufacturers mandatorially have to disclose the technical documentation.) I admit, I found the failure hours after my survey, having come to the conclusion that neither this forum would help me in a timely manner, neither any of those 'businesmen' I interviewed.

So, I would like to express something
- first about the technical solution,
- second about the Fiat business model compared to other automobile manufacturer's business models from a customer perspective with an excourse on your answer.

So first, technical solution: there is indeed a common cause of both the engine failure and the headlights failure. It's the black wire coming out of the ignition lock. There are two wires which should have potential when switched on, one is blue-black, the other one is black. blue-black switches everything else, while black switches the cockpit lights, engine and headlight appliances. The third is red for the starter. My workaround was to cut black and bridge fron blue-black to the engine wires, until I find an honest mech whom I can trust to mount a new ingnition lock (10 mins, 50€ material) IF THERE IS ONE AVAILABLE FROM THAT ****ING FIAT SUPPLY, which is cut off only ten years after the model is abandoned.

Leaving aside that the docs are withheld by Fiat, the reason I did not recognize this just the first time I looked at the ignition lock before my first posting could be counted on me, because I mistook the black wire as 'ground', which was the reading on my multitester. On the other hand, Fiat had been going against the convention that BLACK allways means GROUND. :bang: So after some strenuous thinking, it came to me that there should be no need for a ground wire on the ignition lock, so it was dead.

There is no way that an experienced mechanic with medium mental faculties can miss that single point of failure from my description, and your kind hint proves that.


The Fiat business model from a customer perspective: It seems to be Fiat's policy to feed their dedicated workshops by withholding of technical information and artificial retirement by spare part cut off to induce new sales and repair business. (This makes Fiat one of the worst choices for long-lived vehicles like campervans, where the body is much more worth than the chassis and engine together. I would never ever buy a Fiat camper again.)

Most of the workshops blend well into that business model. Exploits that I was subjected to by Fiat workshops where
- charging unnecessary diagnosis cost (like CrossingKeeper said, if there are no docs you need a 'good mech', who needs hours and hours to check the wires on your expense),
- implanting failures (my v-belt broke; a chief mech told me I needed a new generator; I ordered the v-belt changed; as I watched while they worked, they could not demage my generator, so they loosened the D+ line to make me come back; my generator is fine after 20tkm more now; in situ, they sabotaged my cooler by overfastenig a hose clamp and overfilling, so it broke 100km later (how would you proove?) ) and
- overcharging of spare parts (they bought the only available spare part on the aftermarket and wanted to sell it to me at 500% which was ~€700 while my car was stranded in their workshop; I know because I tried to by the part from the dealer, learning that they bought it 20 mins. before telling me their price).

So, moodrater, please let me talk back to you as well.
Yes, I was questioning their integrity, and most of them proved to be loyal to the Fiat business model, but most failed to show their integrity with their customer.

When it comes to their expertise, how should I differentiate if those guys are dumb like **** or lying bastards (with the exception of the secretary, who is both)?

And, if you might read my post again benevolently, I was not ROFLing about their wish to bring my camper in, it was soleley about the secretary who betrayingly and pitiful played competent missing the fact that there is no such thing as a diagnosis plug in a 1992 diesel Fiat. BTW, the only shop that told me about the ignition lock could not take my camper in because they where booked for 4 weeks. I guess they will change my lock, then, and I will pay an honest price.

If it comes to the documentation: thank you for fully supporting my position. If you allready know that wiring, most failures are simple to find. If you don't, you need a diagram or a lot of time. So it hits me as a customer if I want to fix it myself or the mech hasn't seen the model ever (BTW, if you can profoundly read a diagram, you should allways be faster reading than crawling through a car's intestines.)

Your answer prooves that my description was sufficient to point out the failure, and it prooves also the incompetence or betraying intent of those guys. About the 45 views I had up to then: how many of them follow the Fiat business model and just try to postpone or deviate me to their own workshops instead of honestly answering like you do?

It is not charity to serve a customer with competence, but it is fraud to shake him out with incompetence and the methods described above.

Comparision to other business models: I have had several cars with a star, you know which. I had them repaired and I repaired them myself. There was never a situation where an original spare was missing, even with a 30 year old truck. All dedicated workshops I asked for help every time told me straight out what was the problem, what would be the cost, and sold me the parts I needed; if I was broke, standing in front of their counter, they even directly pointed me to the aftermarket if possible. They even gave me detailed advice on critical repair procedures, like on brakes or injection pumps, and were kind enough to check if it was done right by me afterwards for free.

Another example: I had the generator of another Fiat camper fixed at a free workshop. Because I was stranded. Though beeing booked for weeks, they shoved me in for a quick fix, got a matching spare with 5 times the power of the original, same size and half the price, fixed all that in 3 hours flat while I was surfing on their free convenience WLAN (having free cookies and coffee served) and charged me 45 mins. + the part's cost price. And they shure where just as happy about the deal as I was. Interesting thing: I could watch them working, precise, efficient and quick, and they sure had so much fun! So it was even fun to pay them with gratitude.

Don't tell me these are a charity!

This one is my last Fiat.
 
Hi whiterabbit
Maybe checkout the Talbot EXPRESS Campervan/Motorhome Owners Club & Forum (Peugeot J5, Citroen C25 & Fiat Ducato models) -
http://www.talbotoc.com/portal.php
Maybe it would be good idea to join the forum, it's free, there are a couple of guys on there that might be able to help with wiring diagrams etc as well there is a lot of general stuff with the early Ducatos & its' clones. It seems to be about the only resource available for the early Ducatos etc.
Hope that Helps
 
Hi whiterabbit
Maybe checkout the Talbot EXPRESS Campervan/Motorhome Owners Club & Forum (Peugeot J5, Citroen C25 & Fiat Ducato models) -
[link deleted due to restrictions]
Maybe it would be good idea to join the forum, it's free, there are a couple of guys on there that might be able to help with wiring diagrams etc as well there is a lot of general stuff with the early Ducatos & its' clones. It seems to be about the only resource available for the early Ducatos etc.
Hope that Helps

Thanks a bunch, FreeSpirit. I'll surely join, because my Fiat camper will haunt me again for sure...
 
Fixed! (Partial repost from above)

So first, technical solution: there is indeed a common cause of both the engine failure and the headlights failure. It's the black wire coming out of the ignition lock. There are two wires which should have potential when switched on, one is blue-black, the other one is black. blue-black switches everything else, while black switches the cockpit lights, engine and headlight appliances. The third is red for the starter. My workaround was to cut black and bridge fron blue-black to the engine wires, until I find an honest mech whom I can trust to mount a new ingnition lock (10 mins, 50€ material) IF THERE IS ONE AVAILABLE FROM THAT ****ING FIAT SUPPLY, which is cut off only ten years after the model is abandoned.

Leaving aside that the docs are withheld by Fiat, the reason I did not recognize this just the first time I looked at the ignition lock before my first posting could be counted on me, because I mistook the black wire as 'ground', which was the reading on my multitester. On the other hand, Fiat had been going against the convention that BLACK allways means GROUND. :bang: So after some strenuous thinking, it came to me that there should be no need for a ground wire on the ignition lock, so it was dead.

There is no way that an experienced mechanic with medium mental faculties can miss that single point of failure from my description, and your kind hint proves that.

The solution is somehow hidden in my rant from above, so I think I should point it out...
 
This post contains affiliate links which may earn a commission at no additional cost to you.
Re: Fixed! (Partial repost from above)


Thanks mate. I'll check this out and go for it, if it's that easy. :eek:

(Other ignition locks that went bad in my posession allways needed a special crank-pull-grind-you-know-what tool, only obtainable with a license to kill, to be pulled out...so I was blind to my own habit)
 
This post contains affiliate links which may earn a commission at no additional cost to you.
Back
Top