Potential Fiat Ducato Injector Rust Problems

It’s worth checking the seal against the windscreen and the water drain tubes to make sure water isn’t leaking into the engine bay. There is a black plastic cover to protect the top of the engine where the injectors are but beware as water could get in there and if left unchecked could potentially rust your injectors making them vey difficult to remove should they need replacing. This is particularly important with Motorhomes and camper vans that are often parked up for long periods of time.

[@vazza7504]

Hi Nick, just watched your video, it is a great video and is full of great info to stop this problem. A nice tip for you, before replacing the engine cover what you can do is put a small amount of rubber grease on the socket part of engine cover and the ball part of engine cover inside engine bay. The next time you take off cover you will find it pops of so much easier. This is done on motorbike lugs on side panels and such like, better than snapping the plastic lugs on motorbike side panels using this method. Thanks for video. Vinny. 😊

[@nickharper6436]

Many thanks for the good tip Vinny I’ll do that 👍

[@vintageb3]

I believe copper grease promotes corrosion on aluminium. I think Duralac would be a better choice. Duralac is a highly effective jointing compound which prevents electrolytic corrosion between dissimilar metals. YMMV

[@williamhurley8407]

Correct it does, thanks for pointing this out, I hope everyone watching the video reads this.

[@nickharper6436]

Thanks for the info as I wasn’t aware of this. It doesn’t mention anything on the tin!

[@williamhurley8407]

@@nickharper6436 no problems Nick, and thanks for the warning, something I will be looking out for.

[@michaeldawson6309]

Use ACF50 on any metal as was designed for aluminum on aircraft for this problem. Moisture and corrosion prevention and elimination. Its not cheap but worth it.

[@nickharper6436]

@michaeldawson6309 Many thanks for the info. I’ll price some up 👍

[@syncrosimon]

I have a 2008 Fiat Ducato Swift Moho, I have just had all four injectors replaced, which took Precision Engines in Elgin 16 hrs to do and cost £2300. 3 injectors were seized in, one injector retaining bolt was seized and snapped in the head needing the cam cover removing to extract. 4 brand new Bosch injectors later and she is fine. All water damage. The best thing to do is have a garage every couple of years remove the injectors and grease. This on an engine without rust is about an hours labour. Stitch in time. We travel all over Europe and we wanted this problem looking at here not abroad. So that £2300 was pre-emptive as the engine ran fine. Of course if you are not keeping the vehicle then why bother, except it’s the right thing to do.

[@nickharper6436]

Indeed and sorry to hear of your expense but at least you back on the road again 👍

[@bluerallyes2]

If you’ve not spotted them, there’s two smaller drain holes in addition to the main three. They’re behind the bigger side drains. Keep these cleared too

[@nickharper6436]

Thanks I hadn’t noticed these. I’ll have a look 👀

[@edwarddoyle9231]

Hi good video, to stop any tree debris etc, blocking the drain pipes try some pound shop stainless steel pot scrubbers at the water entry point to work as filters. Ed,

[@nickharper6436]

Fantastic idea, thanks Edward

[@RICHANDLISA1]

Thanks for sharing Nick , helpful as always 👍 It’s made it clearer what the issue is and how to hopefully prevent it. Will be looking at mine next weekend.

[@nickharper6436]

Thanks for the comments Rich. Hopefully yours will be ok 👍

[@michaeldawson6309]

Use ACF50 or the Copper spray Nick used. Nick is a life save

[@moritzfrehse8323]

Thank you very much for showing, explaining and giving highly appreciated tipps for solutions. Kind regards from Moritz from Hamburg (Ducato built 2019). I will check those wholes and pipes tomorrow. So good to know the importance. Have a peaceful and healthy christmas time 🙏

[@nickharper6436]

Many thanks for your positive comments and a peaceful Christmas and a happy new year to you and your family.

[@garrymavin_imotek]

Thanks for the video. I’ve got a 2022 Ducato and had all of the covers and pipes off for cleaning today. There was a lot of debris in the drain channels and tubes and some corrosion on the injectors already. I’ve put a bead of clear silicone between the scuttle panel and windscreen as this looked like a poor fit. The top of the engine under the plastic cover is a perfect trap for water. I’ve removed any surface rust and treated it temporarily with some WD-40 for now but I think AC-50 is a much better option over winter. I think the camper ideally needs to be under some shelter next winter. Not sure if an engine cover would help long term or just trap moisture in.

[@nickharper6436]

Thanks for the comments Gary. I think regular use is the best preventative measure but as you say undercover otherwise. Some of the external screens cover the drain holes and would prevent water getting in the engine bay possibly.

[@kghwanadoo]

I put a drip tray in as my 2013 was dripping onto the engine PO had neglected the drains. The plastic on the windscreen had also shrunk too. I had to make my own tray but it works great. Ford engined wagons are notorious for this problem too.

[@nickharper6436]

Thanks for the comments and glad you got sorted!

[@1884foxy]

Thanks Nick - if mine ever arrives, I’ll try and remember this !!

[@nickharper6436]

Hopefully it won’t be too long 🤞

[@TheVideoviwer]

Hi Nick, Thanks for your very informative video. I have a 2021 Pilote with a Ducato as well and I have the exact same problem. The only way I could unblock it was to fill it with water and squeeze the pipe as you did very low down and hey-presto water gushed out. I've ran a few gallons through it and all is now ok. I've sealed up that useless pipe joint as well and make up some mesh covers for the inlets.

[@nickharper6436]

Thanks for the comments. Yes you have to keep an eye on it but especially if parking the MH up over winter for example. Glad you found it useful

[@bobmoulton3319]

Thanks for sharing Nick , helpful

[@nickharper6436]

No problem Bob and thanks for the comments.

[@colinsmith4958]

Good video Nick, I had the same problem with centre drain blocked. You can access the water exit point under the wheel arch just up behind the liner. I could feel leaves and debris which I managed to remove and unblock. I have made up three mesh guards which I insert in scuttle when van parked up.

[@nickharper6436]

Thanks Colin, I’ll probably do the same as you 👍

[@stevemate8729]

Thanks for sharing this Nick, we have a new Ducato automatic and it's not fitted with an engine cover, the engine layout is different to yo ! The scuttle is not making a good seal with the windscreen and water collects behind. We were aware of this problem with Fiat vans and it isn't a surprise. We have made a simple cover of damp proof membrane and we used neodymium magnets stuck on to the DPM with gorilla tape, it covers the air intake and scuttle and stops the weather and leaves getting in when the van is parked, it's also useful with snow and ice. The cover is very easy to put on and remove, it takes seconds. Another surprise with the new engine: no dipstick !!

[@nickharper6436]

Cool, thanks for the comments Steve. The cover sounds like a good idea 👍

[@warrenlancaster286]

Thanks for the video very informative I will check mine this weekend

[@nickharper6436]

Thanks for the comments Warren and 🤞it’s ok

[@neilwr7442]

Great video Nick. Our 2022 ducato based Twin has same drains. Whilst they run free I was amazed that the Central drain joint still leaks when a large volume of water is flushed down. Not sure if that would actually occur in real life but electrical tape wrapped around jount appears to have sealed it. I've had a passing thought that maybe the fact it leaks if blocked it's Fiats idea of a blockage warning 🙈. As regards the injectors on the new 2.2 multijet I couldn't even see them. Instead of the plastic shield there's large ducting and equipment sat over the top of the cylinder head. That's one way to stop owners checking for rust😅

[@nickharper6436]

Thanks Neil. Interesting thought re the drain 😂 but who knows. These vans have always had a problem with water ingress into the engine bay. Not normally a problem if used daily but if stored over winter who knows 🤔

[@peteroffpist1621]

Same problem as my 2008 Ducato motorhome. Test and fixa asap. And then they did not have the plastic cover over the injectors.

[@nickharper6436]

Thanks for the comments Peter. The plastic cover could make you live in ignorant bliss if you didn’t know what potential problems could be underneath!

[@brianbottomley7000]

just checked mine middle hose leaking badly have put insulating tape right round where hose joins solved problem 2021 ducato 2.3

[@TimmysFavs]

Thanks for the upload on this potentially serious problem. I to have a 21 plate Ducato based motorhome and have been checking periodically, there seems to be quite a bit of water sitting on the plastic cover and inside the heater intake, the three drain holes must be checked frequently to make sure they are free from debris, but on my van the windscreen seal is doing a poor job as the water can be felt virtually all the way along up in under the scuttle. I'm going to attempt to put a silicon bead along the rubber top to see if this helps? Thank you for showing how to remove the engine cover as this is difficult to remove.

[@nickharper6436]

Many thanks for the comments and glad you got some use out of the video!

[@ThreeFineWonders]

For those with scuttle leaking, quality electrical tape on a thoroughly pre cleaned surface works very well.

[@nickharper6436]

Thanks for the tip 👍

[@michaeldawson6309]

Actually I would advise SELF ALMALGAMATING tape we used on telephone cables underground. This will seal the pipe from dripping

[@ThreeFineWonders]

@@michaeldawson6309 If you refer to that stretchy silicon tape that binds to itself, it’s amazing for pipes, yes indeed. However the scuttle is a rubber flap that sits on the lower windscreen glass… so to seal this leakable join the electrical tape works well. Can’t think of a better product to use.

[@Andrew-Dixon]

Good information 👍🏻

[@nickharper6436]

Thanks Andrew

[@salvothegermanshepherd4399]

Thanks for sharing this.

[@nickharper6436]

No worries hopefully it will prevent some nasty surprises for people. It’s Especially relevant of your vehicle is parked up over winter!

[@michaeldawson6309]

Thanks so much for highlighting this. I have a 2019 Ducato motorhome and after removing the black plastic cover which is quite easy I discovered rust forming on the injector nuts as you describe so thank you so much for the advanced warning. To protect against any further water ingress which appears impossible to stop dripping from various orifices above I have customer formed some strong Alcathene plastic to add more protect other than the supplied plastic cover. I have taken note not to allow this anywhere near anything hot. Anyway that sorted to stop future water I then proceeded to rectify the rusting nuts and associated injector coupling. WD40 is not permanent enough so I advise you use ACF50 designed to kill rust, protect and dispel moisture, and provide a future corrosion protective layer. Now ACF50 was designed for the aircraft industry for moisture and corrosion protection and removal. Its sold in spray cans and plastic bottles. The spray cans block up too easy so pay the little extra and buy the bottle. Its not cheap but it will solve the problem. Then check every year clean and apply a little more with a brush. www.mandp.co.uk/products/acf-50-anti-corrosion-formula-1-litre-bottle-k-547736 To remove the plastic hood originally fixed first unclip the little pipe attached on the LHS, then pull with purpose at the rear middle, LHS and then pull sideways away from the final fixing on the RHS. Carefully remove the hood and inspect. This is just a push fit so your not going to break anything. Just watch out when removing the cover you don't knock any electrical connectors. Anyway job done and now part of my annual check. Thank you once more. Mike

[@nickharper6436]

Mike, awesome and thank you for the tip to use ACF50 - much appreciated 👍

[@michaeldawson6309]

I have also discovered why in the video the water was leaking from the black pipe. Basically a stupid design by Fiat. The hose on the RHS pushes onto a MALE connector and butts up against the pipe connector joining the two pipes. So any water running down the pipe first hits this male interface and lip and just runs out as its no way water tight. now the end you examined is a Male connector pushing into a female pipe. So water coming out of the LHS you dismantled can only go inside a rubber pipe unlike the other end that has the pipe over connecting the joining plastic piece ! Like I said a stupid design that will never stop drips. I wrapped some Self Amalgamating rubber tape over the joint to help reduce this drip but still it drips a little. Hence the extra plastic sheet (alcathene) to stop any water getting anywhere near the injectors. ;-)

[@startaylor123]

Fantastic vlog 👏 👌 Had all these issues and others 😏😔 Sadly your windscreen scuttle will warp over the next 2-3 years and create other rain water inlets 😏😔 silicone this in place will solve the issue😊 🍾🍾🍾👍🎄

[@nickharper6436]

Thanks for the comments and I will do what you suggest 👍

[@ktd2956]

Another problem with the drain is the drain on the passenger side empties straight onto the gear box linkage below.if your gear change is stiff and 'clunking' a large dollop of grease over the linkage solves the problem and protects linkage.ive got the plastic cover over the engine on my 2008 citroen relay but this is not guaranteed to protect the injectors.ive just had injectors replaced on my van and the only reason they came out easily with no problems was because i had an oil leak and oil had settled into the well where the injectors sit.another van in the garage at the same time was not so lucky,all four injectors were" welded" into block with rust.head off and very expensive repair!.

[@nickharper6436]

I’ll have a look at the linkage but mines automatic so will probably be a different set up. Lucky you had the oil leak that protected the injectors. Thanks for the comments

[@mikegreen7902]

Thanks Nick. Useful video. My central tube joint leaked as well - I used duct tape to seal the joint. Good to see your windscreen seal is working! My scuttle seal hardly touches the windscreen so I've used more duct tape to seal there.

[@nickharper6436]

Thanks for the comments Mike. It’s seems a bit hot and miss with the scuttle. I’ll have to keep an eye on mine !

[@george150799]

A mate had the same problem, he cleared the blockage and put a Stainless Steel Scourer in the drain holes as a filter, has stopped all the debris and allows the water to flow

[@nickharper6436]

Thanks for the comments George and sounds like a good idea 👍

[@davidhughes7041]

Put pieces of gutter guard mesh into the holes to stop leaves and crap blocking drains clean regularly

[@nickharper6436]

Good idea David

[@geraldoconnor1432]

A little Silicon grease on the plastic lug's mite help.

[@nickharper6436]

Good idea Gerald 👍

[@tonygraham1135]

Hi Nick, just had to have my injectors and ecu replaced, main dealer, £4k!. In the year before purchase van (Twin 600) only did 800 miles so was obviously stood gathering water.

[@nickharper6436]

Sorry to hear that Tony. Was it done under warranty ?

[@tonygraham1135]

2017 van bought 6 months ago. Third party warranty from the dealer, Alan Kerr. Now of course in dispute with warranty company,😢😢

[@nickharper6436]

Sorry to hear Tony. I hope you have some success with the warranty and the dealer. It must be very disappointing for you.

[@MotorhomeTrio]

Thanks Nick 👍🏻 Have a 2020 Ducato and couldn’t work out how to remove the engine cover, was worried I’d break it when attempting to get it off, after watching this video was able to manage it easy. Thankfully like yours wasn’t much sign of rust but gave it a good spraying of ACF50 which is all I had to hand other than WD40, figured the ACF50 would be the better option but quite like your idea of using copper spray. By the way are you located at Aylsham? I’m not too far away from you if so 👍🏻

[@nickharper6436]

Glad you found the video useful and thanks for the comments.

[@Taz6688]

I would be more worried at the water which seems to be going down the intake, I seen a few vans with low intakes and they just pushed the water into the intake system, we had one just lock the engine after going through water, looks like moving it higher is not much better. This problem is on many cars and vans, my Renault drips water onto the coil pack, Alan Howatt had the same with a Ford Ka, it's not going to stop as they push the windscreen further forward over the engine, and use crappy plastics.

[@nickharper6436]

Yep and thanks for the response. I’ll have a look at the intake.

[@JJ_2806]

Hi Nick, thanks for sharing. My skuttle / drains appear ok on my 2021 Boxer, the issue I am having is the seal around plastic next to the coolant, water is ingressing dripping into the engine bay. Do you have any ideas?

[@nickharper6436]

Hi John if that’s where the scuttle seals against the window I’ve seen some put clear sealant there and seems to do the trick

[@Nikki_Holland]

I’ve got a 2014 model and the pipe leading from the center drain hole goes to the right and not the left like on yours so it’s completely away from the engine cover and the injectors. Fiat must’ve changed the design on later models. The drain pipe on mine looks to be about an inch in diameter.

[@nickharper6436]

Cool, sounds like yours will be ok then Nikki. Just check that the scuttle isn’t leaking water into the engine bay where it sits against the windscreen. Sometimes the seal isn’t always good!

[@davidsiddall3224]

Just checked my 21 plate and centre hole is blocked. Poked it then blasted with garden hose and eventually it has cleared the blockage, I will try and find out where the outlet is and see if it restricted, thanks for the heads up.

[@nickharper6436]

I’m glad it prompted you and you found the problem otherwise it would have gone unchecked. I think the outlet is on the front off side wheel well David.

[@tonysummers2334]

Yesterday I sealed the center drain and also put tape along the windscreen to lower trim panel. After some rain last night I checked the engine cover for water. There is still water getting onto the engine cover, it runs down the driver side windscreen wiper spindle. Have you noticed this?

[@nickharper6436]

No I haven’t noticed this Tony but will have a look now you’ve mentioned it !

[@klrrafman]

If there is a part# on the plastic engine cover @6:00 cold you share it, please? The older ones don't have it and that's why top of the engine rusts. Thanks.

[@nickharper6436]

I’m sure there will be but might be different to mine being a 2021 Ducato. I’ll have a look next time it’s off

[@nottslad1211]

Great vid nick I’ve just brought a fiat ducato motorhome and the top of my engine is rusty. So was wondering where did u get the cover for the engine please

[@nickharper6436]

Hi thanks for the comments. My 2021 Ducato came with it already on from new.

[@nottslad1211]

@@nickharper6436 daft question would that cover fit on my 2007

[@nickharper6436]

Not sure to be honest although I’m sure you could adapt it to fit by using zip ties or similar.

[@davidjames1817]

I'm puzzled with this. The metal pipe feeding pressure diesel to the injectors are held in place with a torqued down nut, not a circlip? Are you sure it's not the oil from the filler cap fiasco that hasn't caught fite 🤔

[@nickharper6436]

Thanks for the comments but I’m not sure what you mean. Mine is ok and just a precaution to prevent potential rust problems.

[@MANTLEBERG]

The passenger side wiper stops the water draining into the bottom of the moulding, prop it off the screen.

[@Bartezz]

What do you mean pop it off the screen?

[@tonysummers2334]

Does the engine cover cause more problems than it cures? I wonder whether to leave the cover off and regularly spray WD40 or similar over the injector area.

[@nickharper6436]

Potentially it does if you don’t do regular checks Tony but it’s fairly easy to remove and does offer some protection. It’s just if your unaware of this problem and never look underneath! I personally think if you do regular checks and spray WD40 or similar then to leave it on would be better.

[@tonysummers2334]

@Nick Harper Thanks for your thoughts. I've just been out and modified the centre drain. The connector that joins the two pieces of pipe I removed and cleaned. Then I applied sealant to the joint off the top hose and connector and cable tied it too. The lower pipe can still be pulled off. It appeared that male/female interface is the wrong way on the top hose allowing water to run out. Thanks for your video.

[@michaeldawson6309]

@@tonysummers2334 What a silly design FIAT have where the rubber pipe from the top pushes onto plastic connector as a Female Pipe onto a Male connector a problem made in design as water will always leak unless the rubber pipe fitted inside a connector like it does on the opposite site leading to the floor :-( Doohhh FIAT

[@hustletvhhsn2016]

Excellent video I would never buy a FIAT (Fix It Again Tomorrow) that's why

[@lucamatteobarbieri2493]

fix it again Tony (jokes aside thanks for sharing)

[@colinsmith4958]

Fix It Again Tomorrow (I get told) 🤣

[@nickharper6436]

😂

[@sinyrom]

😢😢

[@matthewtoomer2181]

my van doesnt even have the cover and when water gets on it my electrics go bonkers

[@nickharper6436]

That is a problem, maybe try sealing where the scuttle sits against the glass. I’ve heard that can be a problem!

[@AutoMotohowto46]

use brake fluid