P0638 Fiat Ducato 3.0 2007 Fault Code
usertrialsrider
Posted: 14 July 2016 2:34 PM
Subject: P0638 Fiat Ducato 3.0 2007 Fault Code
 


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Well I decided to buy a cheap code reader after the engine management light came on. Plugged it in and code P0638 comes up. It says throttle actuator control range / performance bank 1. Was wondering if anybody could explain the possibilities of what this means ? The engine light is not on permanently. It seems to come and go.
usereuroserv
Posted: 14 July 2016 2:58 PM
Subject: RE: P0638 Fiat Ducato 3.0 2007 Fault Code
 
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Hello,

This most likely refers to a problem with the throttle body. This is an aluminium elbow with an electrical connection underneath and it is located at the front of the engine between the head and the radiator assembly above the inlet manifold. Early versions of this vehicle have had many problems with throttle bodies and by now i would have thought that the majority have been changed for the later version.

There is a metal flap inside the body that should return to the closed position within 20 seconds of the engine being switched off, and this is normally audible. If the flap is stuck or indeed broken, it will be resting in positions that are not as expected by the ECU. It opens and closes during use in order to obtain the desired air pressure in the inlet manifold; the balance of air pressure in the induction system is very important. The light will come on if the ECU has tried to operate the throttle body or the EGR valve and it has not resulted in the required pressure. Sometimes vehicles can carry on being operated for some time without any noticeable effect on the way that it drives but eventually the ECU will throw it's toys out of the pram and invoke a limp mode with restricted power. Once this happens, the problem has to be solved. This will normally involve replacing the throttle body and often the control solenoid will have been over-worked and over-heated and will require replacement too. It is so unlikely as to be able to rule out a problem with the EGR valve itself because they almost never go wrong.

I hope this helps; please do keep us updated.

Nick
usertrialsrider
Posted: 14 July 2016 4:05 PM
Subject: RE: P0638 Fiat Ducato 3.0 2007 Fault Code
 


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euroserv - 2016-07-14 2:58 PM

Hello,

This most likely refers to a problem with the throttle body. This is an aluminium elbow with an electrical connection underneath and it is located at the front of the engine between the head and the radiator assembly above the inlet manifold. Early versions of this vehicle have had many problems with throttle bodies and by now i would have thought that the majority have been changed for the later version.

There is a metal flap inside the body that should return to the closed position within 20 seconds of the engine being switched off, and this is normally audible. If the flap is stuck or indeed broken, it will be resting in positions that are not as expected by the ECU. It opens and closes during use in order to obtain the desired air pressure in the inlet manifold; the balance of air pressure in the induction system is very important. The light will come on if the ECU has tried to operate the throttle body or the EGR valve and it has not resulted in the required pressure. Sometimes vehicles can carry on being operated for some time without any noticeable effect on the way that it drives but eventually the ECU will throw it's toys out of the pram and invoke a limp mode with restricted power. Once this happens, the problem has to be solved. This will normally involve replacing the throttle body and often the control solenoid will have been over-worked and over-heated and will require replacement too. It is so unlikely as to be able to rule out a problem with the EGR valve itself because they almost never go wrong.

I hope this helps; please do keep us updated.

Nick


Thanks for your response. I will have a listen and see if I can hear the throttle body returning after engine is switched off. It would explain why the light is intermittent as maybe sometimes the flap is working and sometimes not.
userGram
Posted: 14 July 2016 9:54 PM
Subject: RE: P0638 Fiat Ducato 3.0 2007 Fault Code
 


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I had the same fault code reading on my 2009 3.0 litre Boxer a couple of years ago.
I removed the throttle body and thoroughly cleaned it, and the internals of the actuating solenoid.
As I believed the problem to be caused by water running off the engine cover on to the solenoid, I sealed the solenoid well and added an extension to the engine cover to deflect the run-off away from the solenoid.
Touch wood, the problem has not re-occurred.
I can post photos of the throttle body assembly if that helps.

G

PS There is a discussion on this issue, albeit centred around the 2.3l engine, at this thread: http://forums.outandaboutlive.co.uk/forums/Motorhomes/Motorhome-Matters/FIAT-X250-2-3Ltr-Engine-problem/34024/

usertrialsrider
Posted: 15 July 2016 8:27 AM
Subject: RE: P0638 Fiat Ducato 3.0 2007 Fault Code
 


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Gram - 2016-07-14 9:54 PM

I had the same fault code reading on my 2009 3.0 litre Boxer a couple of years ago.
I removed the throttle body and thoroughly cleaned it, and the internals of the actuating solenoid.
As I believed the problem to be caused by water running off the engine cover on to the solenoid, I sealed the solenoid well and added an extension to the engine cover to deflect the run-off away from the solenoid.
Touch wood, the problem has not re-occurred.
I can post photos of the throttle body assembly if that helps.

G

PS There is a discussion on this issue, albeit centred around the 2.3l engine, at this thread: http://forums.outandaboutlive.co.uk/forums/Motorhomes/Motorhome-Matters/FIAT-X250-2-3Ltr-Engine-problem/34024/



Yes some photos would be helpful. Thanks.
userGram
Posted: 15 July 2016 9:01 PM
Subject: RE: P0638 Fiat Ducato 3.0 2007 Fault Code
 


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Will do on Monday, when I get home.

G
userGram
Posted: 17 July 2016 3:54 PM
Subject: RE: P0638 Fiat Ducato 3.0 2007 Fault Code
 


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Image hosted by servimg.com

Image hosted by servimg.com

Image hosted by servimg.com

Image hosted by servimg.com

The first image shows the actuator separated from the body before being cleaned up and lubricated. The remaining pictures show the result of the clean-up operation.

G

Edited a couple of times to get the thumbnails to show!

Edited by Gram 2016-07-17 4:16 PM
usertrialsrider
Posted: 17 July 2016 9:09 PM
Subject: RE: P0638 Fiat Ducato 3.0 2007 Fault Code
 


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Gram - 2016-07-17 3:54 PM

Image hosted by servimg.com

Image hosted by servimg.com

Image hosted by servimg.com

Image hosted by servimg.com

The first image shows the actuator separated from the body before being cleaned up and lubricated. The remaining pictures show the result of the clean-up operation.

G

Edited a couple of times to get the thumbnails to show!


That really does help. Thanks. Is it a rad off job to get to it ? Looks a bit awkward to get too. My fault code seems very intermittent. Ive got a family van holiday coming up in 2 weeks and I'm worried the damn van is going to end up on an rac truck with us in it. With work etc I'm gutted but I may have to take it to the garage as I just haven't got the time to fiddle. I'm certain it is the throttle actuator.
userGram
Posted: 17 July 2016 9:27 PM
Subject: RE: P0638 Fiat Ducato 3.0 2007 Fault Code
 


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Yes, the bolts are a bit fiddly.

One in particular needs a flexi drive, a knuckle joint or one of those sockets which allow a bit of movement of the drive.

I managed to remove and replace the throttle body without removing the radiator.

G
userparpot53
Posted: 21 December 2020 12:45 PM
Subject: RE: P0638 Fiat Ducato 3.0 2007 Fault Code
 
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Hi, Do you still have the photos of your Throttle body removal? I have the same issues and am about to start the process so I can try and get the part number to reorder?

Many thanks

Jeff
userDEL
Posted: 22 December 2020 9:32 AM
Subject: RE: P0638 Fiat Ducato 3.0 2007 Fault Code
 
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Location: Surrey Ducato X250 3.0 160 PV Conversion


There are many much wiser than I on here but as I did mine last week encouraged by the various other threads on the Forum I offer the following if it is helpful? I have 2009 X250 3.0 160 Multivalve.
I first removed the air intake pipe at the top centre (2 x Torx screws) I opened the clip and pulled the bend off the end of the pipe running towards the air filter. I removed the nose cones – just a lot of Torx bolts – aided by a lot of WD40 but I left the lower panel attached at the bottom and just tied it in at the top and I could then flex the remaining black moulding - after removing its bolts - to reach the slam panel bolts. The main object being to remove the black painted slam panel (held by 6 x 10mm bolts) and two larger bolts holding the top rad mounts (the rad stays in situ). I then lifted and tied up the Slam Panel at the off-side end to the off-side wiper shaft. Visibility of the valve and 4 bolts was now good, I could see that it was the original Wahler unit but I could not find a useful part number but a search on the Coastal Motorhomes website produced the correct parts, Throttle Body, Gasket and Loom Adapter – provide your VIN and Reg and they will verify that you have the correct part.
Now loosen the clip and pull off the rubber pipe running away to the left from the throttle body and push out of the way leaving you just 4 bolts to finish the job!!
The two against the block were easy and came out cleanly, the bottom left which is a through drilling (open at the bottom) and likely to be troublesome according to other threads came out with lots of oil and a slightly knurled thread and the bottom right sheared clean off with very little effort from me but at least I now had the old throttle body in my hand and could see that the butterfly was jammed about a 1/3 open so at least I was not wasting my time.
Using my Dremel I centre ground the sheared bolt to get a good drill start which I then progressively enlarged until I got the remains of the old bolt out – access was good, it was very tight and did not give in easily but it was removed with the thread was pretty much undamaged.
I had bought 4 new flanged M8x25mm bolts in readiness and I ran them it and out of the 4 holes with my drill until I could spin them in by hand – Important!
The new valve is slightly repositioned on its plate to make the two previously easily reached screws nearest the block now much more difficult to access. I ended up slotting the left hand one so I could use a screwdriver to drive it home and which point a socket will fit but not before or not with my sockets at least.
I would connect the short adapter cable to the valve before fixing it in position but not connect it to the loom until the end so you can move it out of the way to reach the back bolts.
In good Haynes fashion – reassemble in reverse. My EM light did not go out on its own after two starts so I reset it with my code reader and it stayed out – so far - not that I have been anywhere!
userGram
Posted: 22 December 2020 9:04 PM
Subject: RE: P0638 Fiat Ducato 3.0 2007 Fault Code
 


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parpot53 - 2020-12-21 12:45 PM

Hi, Do you still have the photos of your Throttle body removal? I have the same issues and am about to start the process so I can try and get the part number to reorder?

Many thanks

Jeff

Jeff,

I only have photos of the disassembled throttle body when I cleaned it up to get it working.
If you PM me your email address I can transfer them to you, if it will help.

G