General Fiat ducato egr valve and gearbox fault!

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General Fiat ducato egr valve and gearbox fault!

Mark0007

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Hi,
Having brought a fiat ducato maxi 120 multijet 5 weeks ago I have had multiple problems!
To begin with a strange like fan belt screech noise appeared at 2500/3000rpm at 60 mph when pressing down throttle and stopping when releasing pedal.Also have started to notice it is becoming a struggle to sellect first gear and reverse when stopped.Took to local garage who thought it might be a leaking gasket that connects the egr valve.
The following day a heavy knocking grinding appeared on the front passenger side wheel when steering.
Booked in garage for suspect leaking gasket and new bush mount for wheel.
The steering is now fine and now the local mechanic suggests it is not the egr gasket but the egr valve itself.He explains that once the egr valve is disconnected the van pulls superb with no noise.
Looking at the service history a new egr valve was fitted only 9 months ago by a commercial garage in london not far from where i brought the van(110 miles away) and when calling them they agreed to replace valve free of charge.

All this time the dealer whom I brought from has been aware of the problems and has asked for the van to be returned.I had tried to avoid this because of the distance and the time the dealer may need the van(could be weeks!?) Hence why I went about diagnoses myself.

Took van to commercial garage for free replacement egr valve under the warranty of the valve only to get a call that once new valve is connected van runs poorly again so egr valve not faulty possible solanoide or wiring!?
At the same time asked garage to take a look at the gears as they were getting worse thinking/hoping just a simple adjustment.But they have told me they don't think it is any of the cables/linkage but an internal gearbox problem and will probably need a new gear box!!

The van came with a 3 month/3000 mile warranty with only a couple of hundred miles remaining in warranty.After all attempts to sort out these problems myself quickly as I need van for work,I am returning it to dealer tomorrow.

It is a lovely van 2008 with only 62000 with one previous owner serviced every 10k by same garage from new.

Apologies for the long sad story!Just at my wits end and any advice would be appreciated.
 
If you were stuck with the van I'd blank off the egr if it throws a mil you can drill a small hole in the blanking plate. I'd be talking to my solicitor for looking for a new van or at the very least an extended warranty as a gesture of good will.
 
Hi thanks for the advice.My thoughts were to blank off the egr also only a mechanic mentioned it might not be a good idea and could cause trouble later??
Good idea asking to extend warranty.
 
Hi thanks for the advice.My thoughts were to blank off the egr also only a mechanic mentioned it might not be a good idea and could cause trouble later??
Good idea asking to extend warranty.

Ask him what trouble I'd be interested to hear what he has to say.

If egr throws a mil it will be a problem for the MOT. NOx isn't tested on diesels so no problem there.

EGR reduces peak combustion temperature so some people claim higher exhaust gas temperatures are possible which could in theory lead to problems however under hard acelleration the egr should closes anyway.

In practice people usually report lower egts as the average heat introduced by the exhaust gas outweighs the reduction in peak heat in combustion.
 
I'd be getting a possible 2 crucial updates done at dealership as these cover EGR, idle and running issues if they haven't already been done.

Also a common problem is people chucking EGR's at these engines when it's not the actual EGR that is at fault. Good diagnostic carried out by a good technician is the way to go here IMO.
 

Hi. I can’t speak for your particular engine but I had 2 cars with the Jtd engine and both ran badly until I blanked the egr off. They never showed the management light and seemed to run better with less smoke.

The blanking plates are very cheap and the job takes 15 minutes to do, so I would think it’s worth a try if only to rule out the egr as the problem.
 
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Hi. When I blanked my JTD’s I had no holes a complete blank, in fact I made the plates from some mild steel I had laying around.

I think the ones with holes are supposed to be an improvement if the egr is working properly, if it is sticking open you would need the complete blank to show any improvement.
 
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