Technical EGR fault - possible ECU fault?

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Technical EGR fault - possible ECU fault?

JackoHey

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Mar 24, 2011
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Car: 2007 Fiat Punto Grande 1.9 Multijet 130

Hi all,
So, the problem started a few months back when the car progressively began to lose power, most noticeably in between 10K and 20K revs. There was no engine management light on, and the diagnostics at my local garage struggled to read any fault on the ECU. On the advice of a local garage I took the car to a fiat dealer to have a diagnostics done - £90 later I was told that the EGR valve needed replacing (for which they quoted me £313 to do!).
Instead I got hold of a new EGR valve for £58, and got it done at a local garage for not much at all. After fitting the new EGR, the car drove fine; there was no longer a lack of power as I accelerated, and the problem appeared to be solved.

Only, not long after the new valve was fitted I started noticing flat spots in the acceleration, and juddering as I was driving at low revs. It felt at times as if the EGR valve was randomly and quickly opening and closing as I drove along - you could hear this slight hesitation in the sound of the engine when this happened.
Other problems that have occurred since then are that the car sometimes struggles to start (despite new glow plugs and a new battery being fitted recently), and a lot of smoke (clear/white) would come out of the exhaust when the engine would eventually get going. The car's performance seems lagging compared to how I've known it, and 2 or so months on from having the new EGR valve fitted, the engine management light came up on the dash. I took it back to my local garage, who when they ran a diagnostics on it, came back with… an EGR fault.

This confused the mechanics (and me), as the EGR valve was brand new - all they could suggest is that I get the part mechanically and electronically tested to see if the electronic part of the valve is functioning as it should. So I did (cost me £50), and the results came back that the EGR valve on it's own (when removed and powered up outside the car) functioned as it should, and that all wiring from the EGR to the ECU was okay. The issue they found was that the ECU was intermittently receiving, or not sensing the earth from the EGR valve, causing the EGR valve to randomly open/close when driving. They couldn't tell without further investigation what could be done to fix this, but suggested that I start with getting the ECU tested (£150).

It doesn't fill me with confidence that even if I get the ECU tested, the fault could still be elsewhere, so I'm not ready to shell out more £££ on this until I know what's the best course of action to take.
I read a while back when I first had this problem, that on changing the EGR valve, the MAF sensor should also be replaced - any ideas on whether this could be what's causing all this mess? Or any other suggestions would be greatly appreciated guys, this problem's really starting to get on my nerves...

Sorry about the essay, and many thanks in advance!
 
Maybe you could take a close look at the earth / grounding around the EGR valve? If it tests good off the car then the issue is with something associated. When I had my Mjet I found it responded really well to some injector cleaner after I had my new EGR valve at around 38k miles...

BTW... you are really over-revving it at 10k - 20k RPM! :ROFLMAO: ;)
 
Maybe you could take a close look at the earth / grounding around the EGR valve? If it tests good off the car then the issue is with something associated. When I had my Mjet I found it responded really well to some injector cleaner after I had my new EGR valve at around 38k miles...

BTW... you are really over-revving it at 10k - 20k RPM! :ROFLMAO: ;)

Ffoxy, you beat me to it, i was going to suggest that mine only revs to 4500 lol.

Anyway, im going to be following this thread with interest as i have exactly the same problem as described. I changed my EGR valve after it completely jammed and flooded the engine with exhaust gas resulting in it stalling every 2 seconds or so :bang:. Changed it, worked fine then noticed the juddering, took it to FIAT, had software update and modified EGR gasket which made it slightly better but still there. Struggles to start on occasion but local garage told me this could be due to battery being too small (previous owner) and not turning the starter motor quick enough.

Been advised that the judder could be injector related as it seems to be on a continuous circuit/timing. Going to redex it when i next fill up but i use shell VPower anyway which has a degree of injector cleaner in it.

Hope we get to the bottom of this soon as it can get very annoying.
 
Reviving an old thread here, did you ever manage to sort the issue? Had a fiddle with mine yesterday and found the link pipe to the egr valve wasn't sealed properly to the manifold. Any to make sure it was the egr valve I blanked it off with a bit of card temporarily. What a difference, solved all my issues, car now drives so much smoother and power delivery is instant and constant. Had a spare gasket lying around so gave that to my dad who will be making up a new aluminium blanking plate for a more permanent fix. Definitely going to keep it blanked off. Been doing research on the alfa forum as my dad usedto have a 147 which is basically the same engine. New blanking plate with small hole in the centre is enough to blank off the egr but also stops the eml coming on. Hopefully have it fitted monday night and will report back.
 
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