EGR air flow valve

[Rocket Rob]

Hi, I’m in NZ and have just bought a 2007 Fiat Ducato 2.3 Motorhome. The engine light came on and the limp mode kicked in - great flipping invention that NOT. Anyway is was diagnosed as being the EGR. My question to all those in the know is can this be bypassed? I know it’s some means to re burn the diesel and reduce emissions but is it really necessary ??

 

[Guigsy]

Unlike Fords and VWs, the EGR system rarely clogs with the 2.3 engine. However, the throttle body (which is also where the EGR gases go back in) was very prone to failure with early x250 Ducatos. The butterfly valve won't actuate and you lose all power and smoke a lot. When you turn off the key, the valve should audibly snap closed a few seconds later. If it doesn't, you've throttle body is probably kaput.

The other failure point is the EGR actuation solenoid. This hangs off the top of the bonnet opening with 3 rubber tubes and a cable going to it. At idle, it should buzz a bit, but stop as soon as you add throttle. If can jam so EGR gases are going though all the time, which also causes power loss.

The engine is set up to run very lean at idle. EGR keeps the temperatures down. Generally it's not worth deleting EGR on the 2.3.

 

[Blue Knight]

Hi, I’m in NZ and have just bought a 2007 Fiat Ducato 2.3 Motorhome. The engine light came on and the limp mode kicked in - great flipping invention that NOT. Anyway is was diagnosed as being the EGR. My question to all those in the know is can this be bypassed? I know it’s some means to re burn the diesel and reduce emissions but is it really necessary ??

No it's not needed at all Rob. In its simplest form you can disconnect the EGR by just pulling the plug when the vehicle is switched off, however; such an action will throw-up the engine management light (EML).

Note: The EML appears because the MAF and the MAP sensors will no longer detect any change in pressures because the butterfly in the EGR will no longer open or close because the power/signal is disconnected...........so there won't be any change to the pressure or air flow through the system, hence the reason why the system detects a fault.

In lots of cases the disconnection of an EGR will allow for a colder air charge (colder air) to enter the engine because it'll take its air source direct from the air intake system only.

All the best,

Andrew

P.S. Why did your vehicle technician say it was an EGR fault in the first instance - what was his thinking behind it?

 

[Stanbrook]

In the words of a true gent:

"A really good point is that the engine has an air filter to ensure a clean air supply and yet the EGR feeds shite back into the air intake duct UNFILTERED Oh Please!
Also and engine burns 3% more fuel to overcome the EGR consequences and thus produces more pollution."

An hour later. At £315 a shot it pays to look after it <Broken link removed>

EGR valve blanking/cheating

Open discussion on the pro's con's of this from your personal experience or that of second party knowledge ......................................?

www.motorhomefun.co.uk

 

[TerryL]

It will almost certainly be the throttle body. It was upgraded and if you can find one make sure the updated wiring is with it too.

I went through the "it must be this we'll change it" routine to the tune of nearly £1000 until I got a proper Fiat Commercial workshop involved who diagnosed and fixed it straight away. Unfortunately anyone else but Fiat doesn't have access to the full diagnostics and consequently lesser ODB readers don't always reveal the full story, just suggest what it might be. The EGR sensor was the first.........................!

^{_{Subscribers  do not see these advertisements}}

 

[Guigsy]

It will almost certainly be the throttle body. It was upgraded and if you can find one make sure the updated wiring is with it too.

I went through the "it must be this we'll change it" routine to the tune of nearly £1000 until I got a proper Fiat Commercial workshop involved who diagnosed and fixed it straight away. Unfortunately anyone else but Fiat doesn't have access to the full diagnostics and consequently lesser ODB readers don't always reveal the full story, just suggest what it might be. The EGR sensor was the first.........................!

Went through the same with our 2007 Ducato. The throttle body has an actuator for the butterfly valve and an electrical connector design that collected water. So either the electronics or the mechanism itself failed from water ingress. Ours was mainly an electrical issue, often after it had been raining. The revised throttle body design (which also requires a replacement bit of loom with a better connector) put the actuator motor and connector on the bottom so water wouldn't pool on it.

The EGR inlet valve is also part of the throttle body, but I think it's actuated by vacuum? And as the Fiat/Iveco system rarely gums up, that part of it is fairly reliable.

Throttle body replacement isn't easy. It's behind the radiator and hard to get at without pulling off all the front plastics and the radiator support across the front. The bolts are often solid on the intake manifold studs too, so there's a risk of snapping them.