EGR faults, 2018 Fiat 2.3 130. Euro 6 (1 Viewer)

[Geomore]

Apologies for the brevity of language, lots to cover on a phone.

Summary: should I go ahead with EGR replacement or is a second opinion a good idea?

Had 2018 Ducato for 4 weeks, history of EGR cleaned and MIL before me. Not known if these were linked.

2 weeks ago, error codes:

P0238 turbo boost sensor A high
P0401 EGR flow insufficient.

Manually Cleared and no further codes for 100 miles.

Booked in to garage. Diagnosed corroded PIN on EGR, cleaned and tested but during cold test after rain it threw codes again, same as above plus:

P0236 turbo boost sensor A circuit range/ performance.

Garage wants to replace EGR, but google suggests EGR rarely the cause And more commonly wiring or throttle body (but this may refer to earlier engines?) .

I located throttle body and EGR. Throttle looks clean inside and springs back strongly of moved by hand. Didn't investigate further.

Removed EGR actuator and cleaned pin (bottom left looking at free plug with clip at top). Valve itself seems very snappy and clean, and when running with actuator removed engine strains when running until opened by hand suggesting OK? Actuator motors out and in Apparently at random every minute or so while stationary, and doesn't seem to correspond at all with demand readings on ODB2. (Not sure if these readings can be trusted on a generic reader).

Short Mexican tune up and no further codes, but expecting codes to return at later date!

Should I go ahead with EGR replace (quoted £900 due to 6.5hr labour according to book), buy an EGR myself and swap over actuator, or get a second opinion about it being the EGR at all. Also warned that turbo may be faulty according to codes (I think unlikely, it's showing 20psi max, not making noise and plenty of pull.

May be coincidence but issue always occurred after heavy rain.

Any advice appreciated, no Haynes manual or wirebook to consult on this one!

 

[pappajohn]

Not sure of EGR location but somewhere near the back of engine....
Have you checked scuttle drains are clear, it could be rainwater overflowing the scuttle and onto the EGR if the drain tubes are blocked.

 

[MisterB]

I'm having an issue with the EGR on a car, i wont go into detail in case the thread moves away from your request for help, i just wanted to add that i found loads of info on youtube and you might find the info youre looking for on there?

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[Geomore]

Not sure of EGR location but somewhere near the back of engine....
Have you checked scuttle drains are clear, it could be rainwater overflowing the scuttle and onto the EGR if the drain tubes are blocked.

I cleared the scuttle drains after the first occurrence, and I assumed it was at the rear, but no, it's forward of the engine, directly rear of the top of the radiator. I guess rain must be from the front while driving.

 

[Geomore]

I'm having an issue with the EGR on a car, i wont go into detail in case the thread moves away from your request for help, i just wanted to add that i found loads of info on youtube and you might find the info youre looking for on there?

I've worked on EGRs before, but these Euro 6 engines are nothing like the old mechanical EGRs that simply gum up. I'm expecting the issue to be far from that simple. Info on this relatively new engine seems sparse, I think the previous Fiat engines that are well documented use pneumatic EGRs not direct actuated.

 

[the1andonly]

Geomore
I have the same engine on a 2017 model. have you sorted your problem yet, if so how?
A quick question at what mileage has this occured and is it a comformatic gearbox?
Do you know the ECU software version? Shown on MES.
There are currently 2 simular problems on the fiat forum

Ducato P0401 P0402 P0236 P0238 and limp mode its 2017 Euro 6, EGR changed, What do I check next | FIAT Ducato

Van is 2017 Euro 6 bought new , now with 26K on clock. Problems started this summer with dash engine light and code P0401 appeared on a country lane at low speed going into a corner so it would be low airflow going in to the engine as it wasn’t ‘working’. Bought FCR and cleared fault, happened...

www.fiatforum.com

the second is

Ducato 2.3 2017 euro6 PO401and PO402 resolved | FIAT Ducato

As you may of read from previous posts about the issues i have had since December regarding fault codes PO401 no engine light and PO402 limp mode Engine light activated I was advised to take to Fiat for a software update which would resolve this issue and improve drivability this was carried...

www.fiatforum.com

second example result was:
All sorted it was a ecu software problem that stopped the dpf regenerating which fouled up the complete egr system caused thousands of ££££ of damage had to replace everything.

So Anybody with a Dual egr non adblue euro6 Ducato get MES and check the dpf is regenerating.
as an example my results. I dont know how representative this is Good or bad.

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[Geomore]

The problem is still there! I have a cheap nasty £5 ELM317 or whatever it is, which I reset the error codes with every time it happens. I'd love to have a proper code reader, maybe I should invest. (Post note, MES looks excellent value, I'll try out the free version) Here's my mileage / error notes I started making towards the end of the year:

• P0401 - Mileage: ?
• P0236 & P0238 - Mileage 40130
• P0401 Mileage 41055
• P0236 & P0238 - Mileage 41733
• P0401 Mileage 42104
• P0401 Mileage 42295
• P0401 & P0402 Mileage 42385
• P0401 Mileage 42700
• P0401 Mileage 43928

I boroscoped the EGR valve and it all looks clean as a whistle inside. Besides the faults, the engine performs very well, plenty of power and turbo sounds/performs like a new turbo should, consistent 26mpg for a huge white box seems very good and

I don't know the software version but sounds like a job for tonight to see if it works with my dongle. YES, it is comfortmatic.

I hope it's not coked up everything like the second thread! My next thing would be the MAF/MAP sensor, which I know very little about because VAG PD engines are the newest I'm used to, but I'd prefer to have a really good diagnostic check before switching out any more parts.

I've been meaning to find a good garage that understands diagnostics rather than "replace because computer said so" but I'm a terrible procrastinator, and there's no fiat/van specialists nearby.

 

[the1andonly]

Sorry for your continued problems.
If you were closer i would suggest coming here to do some testing and if necessary comparisson.
Try to get the free version of MES working first. if you cant i use one of these
<Broken link removed>

i use with alfaobd and also works with MES. the cheaper £10 clones do not.
The USB version from Gendan is quicker than bluetooth.
I will be at old sodbury FUN meeting over easter.

 

[Fontie]

Cześć. Jestem z Polski, mechanikiem samochodowym zajmuję się od 9 roku życia. Jeżeli posiadasz Fiata Ducato 2.3 euro 6 i masz błędy P0401 P0402 to mam 100% rozwiązanie Twojego problemu. Ale nie za darmo, bo wiedzą, że to kosztuje. Znalazłem rozwiązanie tego problemu, dlatego zanim przystąpicie do wymiany niepotrzebnych części, proszę o kontakt. brzozka1089@gmail.com WhatsApp +48537825677 koszt to TYLKO 100 €

Translation below -:

Hi. I am from Poland, I have been a car mechanic since I was 9 years old. If you have a Fiat Ducato 2.3 euro 6 and you have errors P0401 P0402, I have a 100% solution to your problem. But not for free, because they know it costs money. I have found a solution to this problem, so before you replace unnecessary parts, please contact me. brzozka1089@gmail.com WhatsApp +48537825677 cost is ONLY 100 €

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[Lenny HB]

Interesting first post.
No one has mentioned that on the pre 2019 engines there are EGR valves a low pressure and a high pressure one

 

[BouncyBoatFolk]

Isn't carbon inside the exhaust outlet a sign of problems? It should be clean I've read.
Mike.

 

[RM_Marine]

Isn't this just spamming the site

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[westhamman]

Thats what I thought, have not seen that on MHF before.

 

[the1andonly]

This guy was bounced off the Fiat forum a little while ago. Ps it was only 50 there.
If you have a P0401, 402, 236, 238 codes the problem (and solution) is now well known in the twin egr model. There are number of threads and guides on the fiat forum.

Ducato twin EGR Engine with P0401 Code (2016 to 2019)

This does not refer to earlier single EGR systems or to later AdBlu SCR engines. Note this is a guide and not definative. It is up to you to make decissions. It is the result of my investigations of data from many contributors and discussion with...

www.fiatforum.com

if you need help just pm me. (then i'll disclose the £300,000 Fee)