Technical Ducato P0401 P0402 P0236 P0238 and limp mode its 2017 Euro 6, EGR changed, What do I check next

[Dutch Ducato]

Thanks again!
Exhaust is clean as new.
I used the original FP software/reader from the FP dealer to connect the new MAF to the ECU. I’m priveleged to use the dealer’s Laptop and FP software to callibrate things.

 

[theoneandonly]

@Dutch Ducato a lack of P401 does not mean the cooler is not blocked but its a good sign. If you can run the following

This is a template specificaly to hunt for your problem. It includes tests for the LPEGR cooler and turbo issues.
A 10 min warm up then 20mins blast down a motorway at 60mph would be perfect.
A second test would be warm engine the FULL THROTTLE PULL. ie with a nice clear road in front whist in 2nd or 3rd plant the throttle ie full throttle to floor and hold to just before engine blows up well perhaps 3000-4000rpm will do then foot off and wait untill idling again, repeat if possible. here we are looking at how the turbo responds. This diagnosed my A4 turbo was dead unfortunately I ve lost the graph/ results (did it on a colleugues kit)

 

[Dexron]

¿Qué opinas de tapar el tubo que marqué con una X en rojo y conectar en su lugar un tubo de entrada desde la admisión hasta el agr como está marcado en azul?

 

[Fredastaire]

Translation anybody?

 

[Blaalducato]

P0401, p0238 and p0236 cured!!

Done a boost leak test (smoke in the intake) no leaks found

I've been having this issue for best part of 3 years in my Fiat Ducato 2.3 twin egr.

I've replaced boost sensor (behind manifold) whilst I did my glow plugs. Still had p0238 - next replaced the boost solenoid on top of engine behind box where 2 boost pipes go.

No issues with DPF or regens even when EML comes on tailpipes sooty so dpf was suspect.. camera down the dpf whilst it was our shown clean as a whistle and no crack. Previously injectors were faulty and over fueled causing excess smoke and soot (egr was already clogged before this anyway)

Subframe removed on a ramp, exhaust and dpf removed to get access to LP EGR Cooler and pulled out.. tried blowing through it was blocked solid!!

Got a used egr cooler off eBay for £80 off a 2022 Ducato had no soot and when blowing through it was no restriction at all. At same time got a DPF to EGR pipe for £40 and replaced both...

Been 3 weeks and no EML and no soft code / pending code for egr or anything.

Previously on any road if you held the rpm at 1900 for any time it would pop up with p0238 and soon after p0401 got used to driving it so wouldn't come on much since you just speed past 1900 rpm or stay below it..

Cost was £500 labour and took them 5hr and parts for egr cooler+pipe £120... After many years and many thousands WASTED it's fixed.

 

[Blaalducato]

Can't figure out how to post video on here or id show you my old egr cooler how blocked it actually was!

 

[theoneandonly]

¿Qué opinas de tapar el tubo que marqué con una X en rojo y conectar en su lugar un tubo de entrada desde la admisión hasta el agr como está marcado en azul?


View attachment 465976

translates as
What do you think of covering the tube that I marked with an X in red and connect an entry tube from the admission to the AG as it is marked in blue?
@Fredastaire

 

[theoneandonly]

Can't figure out how to post video on here or id show you my old egr cooler how blocked it actually was!

At bottom of reply box on Left hand side is button attach files use this to attach the video file.
On right hand side is blue button to post reply

 

[Blaalducato]

2 videos in 1.. first of egr cooler - tried blowing through it was near enough impossible. 2nd vid is of DPF to EGR cooler

 

[Blaalducato]

 

[Blaalducato]

Unplugged top egr to see if it's bottom or top one, code changed so realised not top one and not to waste money on it. Unplugged dpf sensor as put camera down it to check on condition of dpf.

 

[Fredastaire]

@Dexron , I have read the translation provided by @theoneandonly.
Your proposal follows in principle the modification completed by @Cariou in recent years to blank off the sooty air and breath clean air instead.
I've been thinking also about this position to bring in clean air. It would need a spacer sandwich plate with input tube between the LP EGR bottom face and adjoining elbow adapter to the cooler. (Or remove the elbow adapter.). Then couple the input tube to a suitable paper air filter.
It still faces the general Ducato build problem of lack of room and how do you get at the area to attach anything.
I look forward to you telling us that you've achieved the design with photos of it completed.