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

[Masztiff]

News
I make log one more check the injector correction and come up one more faulty code. Now i have p401 p402.I have no more question about twin egr system..

What is the range of the high egr valve opening in mm ?

 

[Fredastaire]

I had 402; 236; 238.
Changed the MAP and turbo solenoid.
Never seen these codes again.

 

[BobSlo]

I also had the same combination of codes p0401 and p0402 and p0238. In my case HPEGR was not blocked

 

[Masztiff]

I also had the same combination of codes p0401 and p0402 and p0238. In my case HPEGR was not blocked

I have one p236 p238 code in February then no more come up.Just the p401 come up till today morning.Now i have p401 and p402 code.I drive 200 km with logging.
Idling--2000rpm smoot then full throttle smooth.If go to 2000 rpm and then play with throttle (hold 20-30 gas position) the 1 and 4 cylinder injectors goes wrong. The 2000 rpm and hold throttle make the gunning noise and come up the p402 fault.These i think factory problem: My car hesitate from 0 km and didnt solved Fiat.The 2000-2100 rpm critical point on these engine.My HP egr Valve Open just some times and maximum open height: 14 mm.That normal ? The low press valve 4.7 mm thats normal.Each valve follow the Ecu calculated position.

 

[Baz in Kent]

I had p0401, p0402, p0236 & p0238.
Fiat have now replaced my EGR valves, DPF, injectors, intercooler and pipes and updated to v0032 ECU software and FEA1OBAU transmission. After 4 months and many exchanges with Fiat EMEA including regularly writing direct to the CEO, plus posting on Twitter, Fiat supplied all parts FOC (£6k) but I paid labour (£1.5k of which £430 recovered under extended warranty). I have a 2-year parts and labour warranty on this repair work.
According to the dealer mechanic and Fiat expert tech in Italy the problem was caused by the software overfuelling the injectors/system (I had v0023) and the extent of the damage was dictated by the mileage after the original fault codes before the software was updated.
The service bulletin 10.023.19 is, according to them, the definitive solution for diagnosis and repair.
Apparently most vehicles with this issue had it resolved under warranty, I surmise they decided not to issue a blanket recall because of the politics around emissions software.
They assure me I won’t have any more problems in future and the dealer told me they haven’t had any returns post repair.

 

[Masztiff]

I have one p236 p238 code in February then no more come up.Just the p401 come up till today morning.Now i have p401 and p402 code.I drive 200 km with logging.
Idling--2000rpm smoot then full throttle smooth.If go to 2000 rpm and then play with throttle (hold 20-30 gas position) the 1 and 4 cylinder injectors goes wrong. The 2000 rpm and hold throttle make the gunning noise and come up the p402 fault.These i think factory problem: My car hesitate from 0 km and didnt solved Fiat.The 2000-2100 rpm critical point on these engine.My HP egr Valve Open just some times and maximum open height: 14 mm.That normal ? The low press valve 4.7 mm thats normal.Each valve follow the Ecu calculated position.

And Thats absolutly Funny my car till 520.000 km run whitout problems.
Now change the complete engine to 2000 km test engine and the fault come up 20.000 km.Thats Rulette Game.No more Fiat Buy.

 

[Masztiff]

I had p0401, p0402, p0236 & p0238.
Fiat have now replaced my EGR valves, DPF, injectors, intercooler and pipes and updated to v0032 ECU software and FEA1OBAU transmission. After 4 months and many exchanges with Fiat EMEA including regularly writing direct to the CEO, plus posting on Twitter, Fiat supplied all parts FOC (£6k) but I paid labour (£1.5k of which £430 recovered under extended warranty). I have a 2-year parts and labour warranty on this repair work.
According to the dealer mechanic and Fiat expert tech in Italy the problem was caused by the software overfuelling the injectors/system (I had v0023) and the extent of the damage was dictated by the mileage after the original fault codes before the software was updated.
The service bulletin 10.023.19 is, according to them, the definitive solution for diagnosis and repair.
Apparently most vehicles with this issue had it resolved under warranty, I surmise they decided not to issue a blanket recall because of the politics around emissions software.
They assure me I won’t have any more problems in future and the dealer told me they haven’t had any returns post repair.

I dont belive these.I dont.belive for Fiat
My car run with old software 300.000 km.without problem.Then update to.0032.
The new "test" engine run with 0032 software.(Before build in the engine run with the overfuelling old software ????)
Interest question but Fiat not solved the problems.

 

[Baz in Kent]

I dont belive these.I dont.belive for Fiat
My car run with old software 300.000 km.without problem.Then update to.0032.
The new "test" engine run with 0032 software.(Before build in the engine run with the overfuelling old software ????)
Interest question but Fiat not solved the problems.

Were all your components (in service news 10.023.19] replaced with new, especially the DPF and intercooler? Any old parts reused would probably be sooted up or damaged.

 

[Masztiff]

Were all your components (in service news 10.023.19] replaced with new, especially the DPF and intercooler? Any old parts reused would probably be sooted up or damaged.

The new engine all compontents barerly new.Just the dpf no but before install the new engine make controll the dpf and washing, cleaning with turbotec Europe Company.These company control before after the dpf.broken.or clean.The problem now my injectors begin faulty . 2 of 4 have correction problem in MES Log.

 

[Baz in Kent]

The new engine all compontents barerly new.Just the dpf no but before install the new engine make controll the dpf and washing, cleaning with turbotec Europe Company.These company control before after the dpf.broken.or clean.The problem now my injectors begin faulty . 2 of 4 have correction problem in MES Log.

I’m not an engineer but suspect a problem with your DPF if all other components are new and unused.
Of course it’s early for my repair, I’ll have to closely monitor in the coming weeks.

 

[Masztiff]

I’m not an engineer but suspect a problem with your DPF if all other components are new and unused.
Of course it’s early for my repair, I’ll have to closely monitor in the coming weeks.

My dpf values:

 

[Baz in Kent]

Looking back I see @BobSlo mentioned how dirty your DPF output is, did you clean and check this? According to Fiat any unwanted soot - anywhere - causes overfuelling which starts the vicious circle.

 

[Masztiff]

Looking back I see @BobSlo mentioned how dirty your DPF output is, did you clean and check this? According to Fiat any unwanted soot - anywhere - causes overfuelling which starts the vicious circle.

Now Follow The Fiat News:
First check the injectors and check the dpf.Next week go to injector service

 

[kangexpress]

@kangexpress how did you delete the EGRs operation? Is there any easy way to do it? For the UK I'm concerned as to whether it would pass the government mot annual test with EGRs not operational.

You will need someone who knows how to program ECU.
Maybe a tuner or ECU repairer.
For the MOT you just need the right guy.

 

[kangexpress]

Hello
I get the cable and make some logs.
First log Egr Low Pressure Temp.
- Engine rpm
- turbo intake.temp
- egr low press temp
Egr low press temp not higher then 40 celsius.Its normal ?
View attachment 407264

Maybe also record LPEGR position (required and actual).
And also coolant temperature.

 

[Masztiff]

Maybe also record LPEGR position (required and actual).
And also coolant temperature.

The targe and actual no diffrrence.So work good the valve.Just the temp i dont know why maximum 50.

 

[Masztiff]

My theory if the lp egr valve system blocked fully (because low temp) and the egr system didnt work i get immediately faulte code.Thats true or no ?
From yesterday till today driver 600 km and no stored faulty codes.

 

[Fredastaire]

My theory is that it's the filter gauze that gets blocked by soot then stops the flow of incoming dirty exhaust.
Next theory is that the LP EGR itself is working fine and the LP mixer butterfly closes across the fresh clean air pipe from the air filter thus with no recirculated exhaust and little clean air that the turbo is unable to suck air.
With this condition the software is unable to calculate the airflow and thus sets the 401 fault.
This on my Ducato only happens at low road speed, with foot off the accelerator
I'm guessing at higher speed that the turbo can beat the strangling of airflow sufficiently not to set the 401.
.
That's my thoughts.

 

[kangexpress]

My theory if the lp egr valve system blocked fully (because low temp) and the egr system didnt work i get immediately faulte code.Thats true or no ?
From yesterday till today driver 600 km and no stored faulty codes.

You can record:
- rpm
- actual position LPEGR
- desired position LPEGR
- desired boost pressure
- actual boost pressure

Try to record with 30-40% gas pedal and under partial load.

If there is a gap between desired and actual boost pressure, while LPEGR valve open, than your LPEGR is blocked.

If the desired and actual boost pressure is the same than there is maybe some other fault.

 

[Masztiff]

You can record:
- rpm
- actual position LPEGR
- desired position LPEGR
- desired boost pressure
- actual boost pressure

Try to record with 30-40% gas pedal and under partial load.

If there is a gap between desired and actual boost pressure, while LPEGR valve open, than your LPEGR is blocked.

If the desired and actual boost pressure is the same than there is maybe some other fault.