Just came of motorway and Engine warning light came on! I got home, read the fault code on the OBD reader as PO401 (Exhaust gas recirculation flow insufficient detected) What could this be a sensor glitch? Or something more serious? Any idea anyone? I have erased the code for now!

Hi,


The exhaust gas recirculation system is basically where the exhaust gasses are reintroduced back in to the cylinders. This makes them less efficient and reduces the temperature and pressure reached inside the cylinder. Doing that reduces the amount of harmful Nitrogen Oxide (NOx) that is produced by the engine.




A code P0401 most likely means one or more of the following has happened:

• The DPFE (differential pressure feedback EGR) sensor is faulty and needs to be replaced
• There is a blockage in the EGR (tube), most likely carbon build up
• The EGR valve is faulty
• The EGR valve may not be opening due to a lack of vacuum.

Commonly the reason is usually the EGR valve that regulates the gasses going back in to the engine is blocked or not functioning. I would start there remove the valve have a look if it is all sooted up and clean up then replace and see if that helps. If not then
Use a vacuum pump and pull the EGR valve open while monitoring engine RPM's& DPFE voltage. There should be a noticable difference in RPM's with the EGR open
Check the voltage at the DPFE, compare to specified values
Replace the DPFE sensor
Replace the EGR valve

No DPF on the 1.9 8valve engines in the UK, it will most likely be build up of carbon in the EGR valve. A good clean won't go amiss!

Thanks guys! Looks like it's more pointing toward the EGR valve and doe's reassure me better, although, if left to long, I could end up with more problems, need to find some time to locate, diagnose and clean this valve out, only thing is I have tried to download these E-learn manuals to no avail always asks for disk and I tried that even re-labelling the disc, Anyone got any more references, pictures or guide's for maintenance of EGR valve on my car? That would help a lot!

I had a similar problem with the eLearn software Jonathan. I'd installed the app from the image I'd got on the hard drive then burnt the disk. When I uninstalled the app and then re-installed from the actual disk that I'd burnt it worked.

I have found an old thread on this subject, should be similar as it's for the 150 version? Or even the same procedure? https://www.fiatforum.com/stilo-guides/156040-1-9-multijet-150-egr-valve-removal-cleaning.html

I managed to get some time this weekend, possibly not enough for a full scale clean of the EGR Valve, but I gave it a go! I manage to get to the Diaphragm and the intake manifold, it was not completely blocked, but was a kind of damp horrible carbon build up of about a cm on the side, so I got rid of it carefully with a tooth brush and a rag and a bit of carb cleaner for good measure, I could not get the lower pipe off, so could not take EGR completely off the engine, but will try, if I need to do this again? Hopefully a study Alan key will do the job as difficult angle, I cleared the fault code again! Driving the car seems a lot smoother, but engine cut out on me, but restarted within minutes, new code came up, camshaft position sensor, now I 'am confused! I have taken note to the above comments and will be testing the solenoid and maybe a more complete clean! I am however thinking if there is fault with the Valve it might be easier replacing the whole thing completely! I have heard reading other problems with EGR Valve symptoms of other cars sometimes it does not operate when stationary, I don't know if this is the case with the Bravo? Because on my OBD reader it read 9.3% EGR and stayed there regardless of revs, stationary that is!

The fault came up again PO401 while travelling to work, but no stalling! I decided to do a live test with the OBD reader while driving the EGR valve is working as it shows 9.3% then suddenly to 93% Maybe I have an intermittent valve, possibly sticking?

I have fully changed the EGR valve, but still have a problem the car engine cuts out when warm and on the OBD reader says it's the Cam shaft Position sensor! Where is this sensors location? I presume somewhere where the camshaft runs? Little help if you can? Please! Wish I had a proper manual!

jonathan3 said:

I have fully changed the EGR valve, but still have a problem the car engine cuts out when warm and on the OBD reader says it's the Cam shaft Position sensor! Where is this sensors location? I presume somewhere where the camshaft runs? Little help if you can? Please! Wish I had a proper manual!

Click to expand...

See this:

Thanks for that! Was looking in there yesterday, late in the day and all and I have ordered that part: FEBI 28386 Camshaft Position Sensor which says compatible on many sites should be the end of my ignition stalling, hopefully Fingers X


The other thing that confused me was the other Camshaft Position Sensor presumably for the 150 bhp version: FEBI 28130 Camshaft Position Sensor sometimes comes up as sometimes compatible for the 120 bhp which is confusing! I'm 90% certain I have ordered the right one! Looking at the picture!

EGR valve more than likely sooted up, worth a clean if you can diy, car should still drive ok.