Key Code light and rough running

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FourWinds Windsport 6.8L V10
Fiat Ducato 2.5 tdi 1999.

My key CODE light illuminates regularly after driving 5 minutes etc.... Usually goes on and off after 2 seconds when you restart after a break.
Yesterday got to destination, turned off, after two minutes realised needed to move forward a few feet and Code light stayed on for All keys (red and two black). No start.
Reset it by disconnect battery Earth lead and back on - all keys work at least once before light staying on again?

Thought I would start it and see what happens as engine warmed up and upon giving some revs engine revved but sounded patchy, became quite cloudy at exhaust and like it was struggling for fuel. Stuttered and died. EXACTLY the same time stuttering started the CODE LIGHT came on - this happened twice so the two things must be connected?
 
Fiat Ducato 2.5 tdi 1999.

My key CODE light illuminates regularly after driving 5 minutes etc.... Usually goes on and off after 2 seconds when you restart after a break.
Yesterday got to destination, turned off, after two minutes realised needed to move forward a few feet and Code light stayed on for All keys (red and two black). No start.
Reset it by disconnect battery Earth lead and back on - all keys work at least once before light staying on again?

Thought I would start it and see what happens as engine warmed up and upon giving some revs engine revved but sounded patchy, became quite cloudy at exhaust and like it was struggling for fuel. Stuttered and died. EXACTLY the same time stuttering started the CODE LIGHT came on - this happened twice so the two things must be connected?
I would suggest that you remove the CODE Fiat immobiliser, they were notoriously unreliable
 
Hi Eddie. You just confirmed your great reputation with your swift reply!

How to remove the Fiat immobilizer then?

V5 is at home but I do have reasonable amount of tools with me.
 
"If it it can be bypassed, It requires some mechanical ability and dexterity. The Keycode Unit by the steering column talks to the fuel solenoid on the injection pump. This solenoid sticks out of the pump towards the starter motor, ie mounted horizontal, east/west. Remove any pipes, hosing, etc. in the way, eg intercooler hoses. Remove the 3 pin plug, the solenoid is secured with 2 tamper proof torx or hex screws (sorry been a few years since I did one). Once these are removed the electronic section of the solenoid can be removed, leaving a standard fuel solenoid. The 3 pin loom plug has wires from ignition, earth and KCU. Located the ign wire (live with key on), connect this to the fuel solenoid. The KCU box under the dash can be disconnected. Note: vehicle security has now been compromised, the van can now be started without a coded key."

From a previous thread on another site ..Be warned...It is there for a reason .

Kev
 
I would suggest that you remove the CODE Fiat immobiliser, they were notoriously unreliable

Hi, would this account for Hard acceleration causing CODE light to illuminate?

Have now changed earth strap to gearbox. And secured negative post of battery as fitting not quite right enough before. Cleaned connector to glow plug single spade and fuel pump solenoid single spade contact.

If you wait several minutes between stop and start the CODE lamp behaves correctly. If you try within the period the CODE stays lit?

Can't bypass immobiliser until late tomorrow.

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"If it it can be bypassed, It requires some mechanical ability and dexterity. The Keycode Unit by the steering column talks to the fuel solenoid on the injection pump. This solenoid sticks out of the pump towards the starter motor, ie mounted horizontal, east/west. Remove any pipes, hosing, etc. in the way, eg intercooler hoses. Remove the 3 pin plug, the solenoid is secured with 2 tamper proof torx or hex screws (sorry been a few years since I did one). Once these are removed the electronic section of the solenoid can be removed, leaving a standard fuel solenoid. The 3 pin loom plug has wires from ignition, earth and KCU. Located the ign wire (live with key on), connect this to the fuel solenoid. The KCU box under the dash can be disconnected. Note: vehicle security has now been compromised, the van can now be started without a coded key."

From a previous thread on another site ..Be warned...It is there for a reason .

Kev

Hi. Today I decided to have a go at this fix. Chipped off plastic cover and can see circuit board and big chip buried in soft resin. I can scrape the resin away but circuit board seems to go to the edge of the housing on all sides and doesn't appear to move easily.
Do I continue digging?
I am.assuming the power wire I am after is on the other side of the PCB board?
Just being cautious and checking before I go beyond the point of no return.
 
I would suggest that you remove the CODE Fiat immobiliser, they were notoriously unreliable

Hi Eddie. Please see my latest post. I can see the PCB board but unsure where the wire is and how to actually release the board? Carefully picked a lot of soft resin off PCB but not sure what to do now?
 
I'm having the problem should have been in Stratford now happened last year on hols in Yorkshire then was ok again after spending night on recovery truck We drove home in tow car
Off to Spain on ferry 26 August so any info on how to remove parts to make better would be much appreciated hoping to make it to Retro fest first
Thanks any help greatly received as need to get sorted fast and permanently
 
I'm having the problem should have been in Stratford now happened last year on hols in Yorkshire then was ok again after spending night on recovery truck We drove home in tow car
Off to Spain on ferry 26 August so any info on how to remove parts to make better would be much appreciated hoping to make it to Retro fest first
Thanks any help greatly received as need to get sorted fast and permanently
Hi,
1) Have you replaced and added extra earth straps in engine bay?
2) Do you have the yellow or orange KEY CODE symbol on dashboard?
 
Did have orange keycode symbol on but know only 2 red lights come on oil and another might be hand brake and yellow light comes on and of very quickly but hade problems with keycode light as well last year but went away and started to play up again this week should be in Stratford now but wont start at all turns over and can hear pump in tank for about 5 secs after turning key

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Did have orange keycode symbol on but know only 2 red lights come on oil and another might be hand brake and yellow light comes on and of very quickly but hade problems with keycode light as well last year but went away and started to play up again this week should be in Stratford now but wont start at all turns over and can hear pump in tank for about 5 secs after turning key
My 1999 Ducato/Fiat immobiliser when faulty - the KEY CODE light stays illuminated. If yours is on and then off then it probably isn't the fault. Have you added a good earth strap as the older vans had rubbish ones. I replaced from negative post of battery to wing, added a new one from battery to engine and replaced the one from nearside inner wing to gearbox bolt.
When the immobiliser is damaged you can usually turn the engine over as much as you like but it wont fire because your fuel pump is not turned on - thats what the older immobilisers used to do. No fuel, no start.
There is a bypass of the immobiliser on newer than 1999 - some combination of key turns and stepping on the gas pedal, in the manual. For me it meant a sharp knife and small chisel and removed a plastic cover to get at the positive feed to the fuel pump. Private message me if you want more detail but like i said, when ine played up the KEY CODE stayed ON.
 

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