Fiat Ducato 2.3 Adria Twin 2 fault codes and blown fuse

[Selseymech]

Whist travelling at about 50mph, the engine management light came on and the van went into restricted performance,the codes are P0403 and 0638.These symptons have been mentioned before on here but what was the cause? The EGR solenoid is stuck I am sure and I thought that was the culprit for blowing the fuse so I disconnected it but the fuse still blows.Any ideas?
Thank you

 

[gus-lopez]

 

[Phill D]

0638 is throttle actuator control. You don't say which fuse.
The other code is egr so I guess it's that circuit has a short of some kind.

Welcome

 

[Selseymech]

Hi Phil and thanks for your response.My apologies the fuse is F17 (10) in the engine compartment.The codes came up together almost definitely when the fuse blew.Ive disconnected the throttle body and EGR solenoid but still a short circuit.A circuit diagram would be nice-Ive scoured the web to no avail !!!!

 

[Googlebot]

I can’t upload a manual as it’s too large, do you have an email address you could PM me?

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[Googlebot]

Ah, here it is. Not sure it’s the correct one though but might help.

 

[jockaneezer]

I had a fault with the EGR valve on my last car but it was the vacuum solenoid that operated it that was at fault. The wiring had chaffed through and it blew a mini fuse in the supplementary fuse box. A bit of insulating tape and a cable for fixed it.

 

[Selseymech]

Hi Googlebot and thank you very much indeed for the manual, I haven't studied it in detail yet but from what Ive seen it looks to be very useful indeed it is very much appreciated.For a popular vehicle made in the 1000's it is amazing how little information is on the internet!!
Once again many thanks!!

 

[Selseymech]

I had a fault with the EGR valve on my last car but it was the vacuum solenoid that operated it that was at fault. The wiring had chaffed through and it blew a mini fuse in the supplementary fuse box. A bit of insulating tape and a cable for fixed it.

Hi Jockneezer thank you for that information all very useful, what a great forum this is!!
The fuse in question F17 (10A) in the battery compartment is identified as "E.I primary services" whatever they may be! So its a question of elimination disconnecting the various sensors until the short clears.I'll hopefully report back when Ive found the fault.Thanks again to all contributors so far its nice to know Im not alone!!

 

[jockaneezer]

Have a look at this thread Selseymech,

E.i. system (primary services) F17 10Amp Fuse

Continuing on from P0403 and P0638 fault codes in earlier post under EGR blank plate............. Just removed, stripped down and cleaned every fuse and relay in the fuse box that sits in the engine bay on the nearside. (see attached photos) Noticed that Fuse F17 E.i. system (primary...

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[Selseymech]

Thank you I’d seen that and my eyes lit up that’s exactly the symptoms.Last night I systematically disconnected each sensor from the wiring loom until the short circuit on F17 disappeared.Eventually I found the culprit, it is a sensor mounted behind and just above the MAF housing in a vertical rubber hose leading up to the top of the engine (breather?) With this sensor disconnected I checked th resistance to chassis and all was well.I then connected the fuse and battery and was able to clear both fault codes.Any ideas what that sensor does? Had enough last night but I’ll investigate further today.Good lesson here if you’ve got more than one code it’s more than likely a common fault /supply this could of cost a lot of money by replacing perfectly good components and still had the fault.Thanks to all contributors for your help

 

[jockaneezer]

Can you post a picture of the sensor ? What size is the rubber hose, 12 mm diameter and up might be a breather hose, 8mm and below might be a vacuum hose ? I'm not familiar with the Ducato engine and was wondering if it was a vacuum pipe coming from the vacuum generator on the end of the camshaft ?

 

[Selseymech]

Good morning sorry for delay Ive just subscribed!! Attached hopefully is a picture of the sensor/valve? It is T'd off the main air intake hose after the MAF sensor and the pipe is approx 1" o/d.it goesup to the top of the enginge where it enters a black box.The other side of the black box is connected to the engine also.