Technical EGR (again)

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Technical EGR (again)

TwyRob

Now a SAAB owner
Joined
Nov 27, 2006
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Hi guys,

Think EGR is wrecked. Fiat say Diesel Pump Vacumn valve/sensor/something but it feels like the EGR. No power up to 2000rpm when warm fine when cold. Flies like a jet plane (not literally) after 2000rpm.

Seems to be worst after holding the revs just below 2000. Happened after stupidly buying Tesco diesel, could be a conincidence though.

I've tried fuel cleaner from Fiat and better for a little while, also checked air filter and better for a little while.

Seems to clear if I stop, switch off and then switch on and rev like crazy. Get black smoke and then all is well.

Any ideas?
 
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Sounds similar to when Mrs_G's EGR valve failed. I understand you can blank it off to test to see if it's stuck open.

The tech at my local garage held on to the ribbed metal pipe that connects to the egr valve. With a cold engine the pipe heated up almost imeatiatley indicating the EGR valve was stuck open. After he removed and cleaned the valve the van was back to its old self. Mrs_G must have done 80-90,000 since then with no repaet of the problem.
 
Unplugged the EGR (electrically) and the problem is solved. I know that it it illegal to drive but it's far safer than being a sitting duck on rounabouts and junctions!

The car is booked in for Tuesday, I'll tell them what I have done and the result. Should be fixed same day. Hope it wont do any damage diconnecting the EGR in this way, need to be able to drive safely until Tueday.

Thanks for the reply, it just felt like the EGR.
 
Sorry to sound like a fool but how did you disconnect. Is it as simple as pulling a fuse. Mechanic said he looked at mine and that it was working fine. The pipe doesnt get hot when running. Still getting same problem as you.
 
I could end up sounding like a fool in a minute!

I unplugged a grey plug from the back of the EGR. :idea: Unless I unplugged a grey plug from some other component but I'm 99% sure it was plugged into the EGR.

I dunno if it was a sensor or the power to the unit but it solved the problem. I plugged it back in last night and drove to work this morning (18 miles) and the car behaved perfectly! :confused:

This is quite odd, I'm still dropping it off at Fiat tonight, I'll see if it plays up before then and what they say if not.

I'll let you know how it goes. You could try unplugging it though, here's some instructions:

*make sure car is running ok first (i.e. cold and smooth accel. in my case) otherwise it might just stay running badly.*

1. Remove black plastic engine cover (four bolts) , don't forget to take oil filler cap off first.
2. Locate EGR (as long as this is the EGR!) I think it is the unit at the rear of the engine, at the top slightly to the right.
3. Locate grey connector plug that is plugged into this unit.
4. Unplug it.
5. Re-attach the engine cover.

I only tried this after consulting with a collegue who used to work as an automotive engineer (now a DT Teacher) who identified this part as the EGR. I also fully intended to reconnect the unit after a couple of days to see if the problem returned, thus identifying the problem!

Disconnecting the EGR is apparently illegal because of NOX gases being released into the atmosphere instead of being removed by the engine when it is connected.

I should also add, I am not a mechanic and have limited knowledge. This should not be considered informed advice, simply something that worked for me.

Robin
 
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If you do a search there is another thread on the forum which is highly detailed with pictures on how to find/disconnect/to to repair the EGR valve on the Doblo.
 
(From DPF thread)

I've been having a think. I've had a few electrical niggles when starting the car recently. Things like ABS failure, oil temp exceeding maximum, oil pressure too low. All of these go away immediately.

The engine failure message came on when starting the car this time, not while driving like last time. I think I might have a bad battery, the little indicator ball on the battery is white - "refill fluid". Sound plausible?

Getting it checked on Monday, I'll probably get a regen done if the codes say so then a new battery I think. Any opinions?

Well, battery was knackered. I have a new battery and none of the random codes have come up. Going to get the ecu read and codes cleared at 2pm. Hopefully this has just been electrical gremlins!

Alas, my EGR is broken. (battery was broken too though) EGR is stuck closed. Fiat want £358 to fix. Booked in with an independant on Wednesday. Damn it! No Christmas for us then.

So, a different Doblo and the same problem. I hope the independent (above) charges less than FIAT for a fix! Why can't one thing break at a time?
 
I thought I'd let everyone know, it's fixed. £125 for the part (I think it was electrically broken) plus labour. :)
 
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Glad you got it fixed. Our Dobby keeps misbehaving when wifie-poos drives it, but I can't get it to repeat the fault as it is only intermitent. Basically won't rev + cant get above 20 mph, then will eventually sort itself out. She hasn't noticed any warning lights. I suspected it might be a "fly by wire" throttle problem, but it could also be EGR, I suppose? Will have to see my mate with a fault code reader.
 
We have a 1.9 JTD ELX on an 02 plate.
It has played up with me as well now. Just seemed totally gutless, although it did improve after I planted my foot until we reached 4500rpm+. Current mileage is around 104k.:confused:
 
Disconnecting the EGR is apparently illegal because of NOX gases being released into the atmosphere instead of being removed by the engine when it is connected.

This is incorrect. NOX gases are not removed, they are only reduced. It NOT illegal to remove, blank off the EGR here in the UK.


The EGR on the 1.9 JTD engine is well known for sticking open and causing power loss. Its caused by a build up of crap(soot etc.) on the valve that physically stops it shutting when power is needed(EGR should close when power is required).

Here's a Stilo guide(same engine I believe) on how to clean the EGR and prevent this problem.
https://www.fiatforum.com/stilo-guides/263681-clean-egr-valve-1-9jtd-8v-engine.html

This is a short video of the EGR on my car after I'd given it a clean.

[ame="http://s296.photobucket.com/albums/mm189/Shadeyman67/?action=view&current=04072011075.mp4"]04072011075.mp4 video by Shadeyman67 - Photobucket@@AMEPARAM@@http://vid296.photobucket.com/player.swf?file=http://vid296.photobucket.com/albums/mm189/Shadeyman67/04072011075.mp4@@AMEPARAM@@vid296@@AMEPARAM@@296@@AMEPARAM@@mm189/Shadeyman67/04072011075@@AMEPARAM@@mp4[/ame]

Only takes an hour to remove and clean. Some people blank the EGR off to prevent the problem reoccurring.
http://www.ebay.co.uk/itm/EGR-blank...UZUKI-1-9-ALFA-1-9-2-4-CADALLAC-/110806067098
 
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Hi.
Had similar problems.

replaced EGR with one off E Bay (kept the old one to clean as a spare)
Put a 3 hole restrictor plate on it and not had a problem since.
Also use 2EHN (E Bay again)when filling up and seems to have improved running.

Hope it helps.

Ed.
 
How do you. Get to the fuel pump on a fiat doblo

Hi,
Welcome to Fiat Forum.
we need a bit more information to be able to help with your question.
1/ What engine is fitted to your Doblo?
2/ What year is it?
3/ What fuel pum are you referring to?

A search of the forum might help you but can produce a ot of data. Fuel pump questions are not normally associated with EGR issues and this is an old thread so a new thread might get more response.

Robert G8RPI/
 
This is incorrect. NOX gases are not removed, they are only reduced. It NOT illegal to remove, blank off the EGR here in the UK.
<SNIP>

Old post I know but it's been "refreshed" so I have to say that the above comment is incorrect. it IS ILLEGAL to disable emission controls on any road car in the UK (and most other countries) This includes catalyts, EGRs and DPFs. If they were fitted at manufacture they have to stay, even if they were not needed to meet the regulations when the car was new. Passing an MOT does not "approve" or legalise the modification. As a minimum you would have to declare it a modified car and undertake a Single Vehicle Inspection to make the modification legal in the UK.
The restrictor / swirl plate is a Fiat modification and is legal.

Robert G8RPI
 
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