Technical 2007 Grande Punto 1.9 130bhp Multijet EGR Valve Fault

[Mattty]

Hi,

I recently purchased a Grande Punto 1.9 diesel sporting, but I have been having trouble with the EGR valve. The first night I had it, I did a diagnostic check on it and it came up with a faulty EGR. I removed the EGR valve and cleaned all the soot out. I then reassembled the EGR and reattached the electrics. The engine light stayed off for about 3 miles then came back on again, and the diagnostics showed an EGR fault again.

After this, I replaced the EGR with a genuine Pierburg valve and ran it. I experienced hesitation at 2000-3000 rpm, but the engine management light stayed off. I then replaced the new EGR with the old one, as it didn't hesitate. I sent the new EGR valve back, thinking it could have been faulty.

I had read on the forum that some owners blanked the EGR off completely which seemed to cure it. I tried this and it worked for about 40 miles and the light came back on. This then prompted me to order another new genuine Pierburg EGR. Instead of actually fitting the valve, I connected the EGR electronically and cable tied it to a bracket behind the engine.

With the my dual EGR valve setup, I ran it again. The light stayed off for another 5 miles, then appeared again, and indeed, the fault code on the diagnostics said EGR valve fault. After this frustration, I removed both EGRs and dismantled the old one further. It turned out that the old one wasn't opening at all.

Could there be something else wrong? ECU maybe? Or was it just coincidence that I purchased 2 faulty EGRs?

Many thanks,
Matt

 

[cobalt01]

If egr isn't opening or closing then it needs replacing. Get yourself a egr valve and then change it. After you've done this clear the error from the ecu. This should help has the ecu not got a stores egr error code now. If that doesn't help I'd look into the electrics.

What diagnosics are you using? Try multiecu scan (if not done so) this may give you a more in depth message as may not just be the egr valve causing the issues. It's like dealers diagnosics not a 3rd party multi odb 2 reader

You can get an genuine egr for £134 including forum discount from shop4parts (don't knos what paying for the one you said)

 

[Mattty]

Thanks for the quick reply! I have replaced the EGR twice and cleared the faults both times. Still not working!

My dad is a mechanic and owns a Launch X-431, I have been using that.

I've just read a post online stating the map sensor could be causing the EGR to misread the signals sent to it. I've just removed it and it's sooted up, going to see if this will keep the light off.

Has anyone else had any trouble with this?

Many thanks,
Matt

 

[cobalt01]

I haven't has have a petrol gp. Yes the map sensor can cause issues. Doing a good clean won't hurt

 

[Se7enHP]

I certainly have hesitation at around 2000 rpm... I am certain it is the EGR as all pipes leading to the turbo are sealed and creating good pressure.... I have ordered an EGR blanking kit and will be fitting his soon... I will let you know the results

 

[cobalt01]

Even with a blanking kit i would of thought you'd have issues due to ecu looking for the egr and not there. You'd have get a remap to prevent this. Could be wrong

Hopefully it will get sorted soon enough for you

 

[Mattty]

I certainly have hesitation at around 2000 rpm... I am certain it is the EGR as all pipes leading to the turbo are sealed and creating good pressure.... I have ordered an EGR blanking kit and will be fitting his soon... I will let you know the results

I have read online that a swirl gasket can be added to remove the hesitation. This may be worth a try? It's like a blanked gasket but with 3 small holes drilled through in a triangular shape.

 

[Mattty]

After cleaning the map sensor and running it today, the light has come back on with EGR fault again.:bang:

Although the light is on it's not effecting the performance of the car, so I'm going to have another look tomorrow

 

[g8rpi]

I have read online that a swirl gasket can be added to remove the hesitation. This may be worth a try? It's like a blanked gasket but with 3 small holes drilled through in a triangular shape.

Hi,
I have a 1.9 16V mJTD 150 HP (Croma) so slightly different engine, but I fitted a restrictor plate and it improved things . I hadn't got to the point of problems, but did a precautionary MAP & EGR clean and fitted the restrictor. Drivablity was improved as was fuel consumption. I recommend it. I used a genuine Fiat restrictor and put a guide in the Croma guides section.

On the engine light, have you done a full scan for any other fault codes?
Also check to make sure connections are good and no pipes are blocked.
I was able to operate my valve off the car by applying 12V.
It could be an ECU problem. You can check it by un-plugging the EGR valve connecting a voltmeter to the loom nd measuring the voltage. It should be about 0V at idle/cold, and increase as you rev the warmed engine. You can use a small bulb (interior or sidelight) instead of a voltmeter. Remember to measure across the pins, not one pin to ground.The diagnostic unit should be able to display the EGR command, the measured voltageshould track the command. If the voltage is fixed at 12V (12-14V, about the same as your battery, 12V is nominal) EGR open you have a ECU fault or a short to ground in the wiring. If you get zero volts, check between each pin and ground (Chassis). one should be at 12V with engine running. If this is missing you have a blown fuse, broken wire or bad connection. If 12V is there to ground but not across the pins you have broken wire, bad connection or possible faulty ECU.

HTH,
Robert G8RPi.

 

[Mattty]

Thank you for your detailed input Robert! I believe I have fixed the issue! :slayer:

I replaced the map sensor with one from my dad's Ducato, which has the same part number as mine. This stopped all hesitation with the original gasket installed, and no sign of the engine management light (fingers crossed)!

 

[g8rpi]

Great news,
The MAP sensor is fairly cheap, about £20 on ebay.

Robert G8RPI

 

[cmosfxx]

Great news,
The MAP sensor is fairly cheap, about £20 on ebay.

Robert G8RPI

yeah... cheap chinese sensor maybe

Go for original parts only

 

[Ckem247]

Remap it with the egr blanked

 

[tjscotton]

i second this, even if you dont have money or want the remap - i got my EGR mapped out for £50, took all of 20 minutes and now I dont have to think about it!

 

[g8rpi]

i second this, even if you dont have money or want the remap - i got my EGR mapped out for £50, took all of 20 minutes and now I dont have to think about it!

Apart from the fact that it's illegal in the UK! Yes I know that the MOT tester can't tell easily, if at all, but you have just told the world on a public forum.

It is also becoming increasingly common for insurance companies to access ECUs following a claim. This is mainly to get evidence of speed etc (many ECUs store data when a sudden stop happens), but if they see changes and you haven't told them your insurance is invalid

Robert G8RPI.

 

[tjscotton]

Apart from the fact that it's illegal in the UK! Yes I know that the MOT tester can't tell easily, if at all, but you have just told the world on a public forum.

It is also becoming increasingly common for insurance companies to access ECUs following a claim. This is mainly to get evidence of speed etc (many ECUs store data when a sudden stop happens), but if they see changes and you haven't told them your insurance is invalid

Robert G8RPI.

Understood, but the likelihood of an insurance company going that far to understand the cause of a crash is extremely unlikely. An ex-police officer I spoke to said that unless there is a fatality the chance of the police or an insurer for that matter actually bothering to do more than a visual inspection is highly slim. I get what your saying about insurance being invalid but I'd rather personally, enjoy a working car that isn't coughing and spluttering at 2000rpm for my time owning it that is affordable because the insurance isn't bumped up due to a completely non-performance enhancing alteration to the ecu. Each to their own I suppose but unless the insurer could prove the EGR bypass was the cause of your accident then they'd have a pretty hard time voiding insurance over something like that. That's just my opinion though I don't think it's anything to worry about.

I'm personally with an insurer that has all mods declared but most companies will do anything to get some extra cash out of you

 

[g8rpi]

It's getting easier to check ECU's, just plug a laptop in. They don't have to prove that the undeclared modification had anything to do with the accident, just that you did not declare it. EGR / DPF/ CAT deletion is a catch 22, you can't declare them as they are illegal. This can lead to a unpaid claim and possibly a conviction for un-insured driving. I'm not willing to run the risk. If you are having trouble with hesitation / stuttering try the Fiat approved restrictor / swirl plate, it worked for me.

 

[Mattty]

After driving to work today, I realised that my engine was still hesitating...

After a little research into the map sensor I have fitted, it turns out it was not designed for my engine!

I have now replaced it with the correct sensor, but I'm still experiencing hesitation... :bang:

I've plugged the diagnostics in again, with no faults showing, and I have reset the ECU. Hopefully it will start learning the sensors etc. again.

 

[tjscotton]

Did you replace your MAP sensor (next to the EGR held on with a single torx) or the MAF (next to airbox) bc if you replaced the MAF its probably worth cleaning the MAP... they get pretty coked up with carbon, same as the EGR.

 

[Mattty]

Did you replace your MAP sensor (next to the EGR held on with a single torx) or the MAF (next to airbox) bc if you replaced the MAF its probably worth cleaning the MAP... they get pretty coked up with carbon, same as the EGR.

Replaced the MAP sensor. It's kept the engine management light off, which proves that it was the fault rather than the EGR valve itself. Just have hesitation again. I don't really want to blank the EGR off as my dad has had cars come in with melted pistons, due to them blanking it off.