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.

 

[Cariou]

HELLOFor about a year, I've been cleaning several of them for colleagues, using only the two screws on the 3-way valve to vent the smoke. This is done with a heat gun. Be careful, the cooler gets very hot. This allows you to check the variation of the fault codes.
bonne journée

 

[Fredastaire]

@Cariou thanks for adding the photo.
.
How do you reach the two fixings screws? Do you remove the plastic battery box for clear access?
.
On your friends Ducatos have you then followed to blank off the DPF and fit your fresh air filter?

 

[Cariou]

re
j avais enlever les 2 boulons par le bas et boucher le fap avec une plaque de tôle ronde épaisse plus le collier
j avais aussi penser aune entretoise mais la sonde de température est avant le haut de la jonction et je ne voulais pas qu elle soit perturbée
j avais également pensé faire une entretoise avec un tiroir et un tamis fin interchangeable dans ce tiroir ,j ai abandonner car je ne voulais plus être emmerder avec ce systeme
bonne journée
I removed the two bolts from the bottom and plugged the DPF with a thick round sheet of metal plus the clamp.I also considered a spacer, but the temperature sensor is before the top of the junction, and I didn't want it to be disturbed.I also thought about making a spacer with a slide valve and an interchangeable fine screen in this slide valve. I gave up because I didn't want to be bothered with this system anymore.Have a nice day.

 

[Noel13]

As far as I can tell the LPEGR and the HPEGR are opening and closing as expected from the run I have but I did not record the temps. The van is not with me now to do further testing. The LPEGR values jump up and down as expected for a blocked cooler- I am just trying to work out what is causing the faultcode in this instance.

I have been getting these codes on my 2021 Ducato & after checking all I got a can of diesel fuel cleaner & all is right now.

 

[Dexron]

Good morning.
Sorry I couldn't translate my previous message; I couldn't translate it from my phone.

My Ducato 2.3, 150 hp, with 580,000 km, has fault P0238.
The fault persists, and even after clearing it, it appears after a few seconds. The van goes into emergency mode and loses power, forcing me to stop.

After removing the high-pressure EGR valve, I didn't find the carbon deposit I expected. There was a carbon deposit with oil in the turbocharger-side intercooler (which was expected). I don't think it's a good idea to remove the cooler strainer; too much carbon could enter the intake system and cause other problems.
The pressure sensor was clean; it's fitted with an old part number; it has been replaced, as has the turbo regulator. All the vacuum lines have been checked and are in good condition.
The exhaust shows a lot of soot, possibly a DPF fault.
I'm thinking of disassembling the low-pressure EGR and DPF to clean them.

I'm including some photos so you can see the condition of the parts.

 

[Cariou]

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?

Hello,It will work, but maybe start by loosening the two bolts to ensure air intake and then do a road test to check for defects.

 

[theoneandonly]

I have been getting these codes on my 2021 Ducato & after checking all I got a can of diesel fuel cleaner & all is right now.

Which codes have you got? Have a read of this, its a bit easier than 80 pages.

Twin EGR Problem

This does not refer to earlier single EGR systems or to later AdBlu SCR engines. Note this is a guide and not definative. It is up to you to make decissions. It is the result of my investigations of data from many contributors and discussion with...

www.fiatforum.com

I strongly suggest you get Multiecuscan (software for a windoze laptop) and an appropriate adaptor. THere are Austrailian member who can advise as to best source over there. Once you have it sorted do a test run with my std template 4. i will post when ready, once you can post the results here as a csv file and i will post my analysis here or PM.

Tutorial to Measure specific Engine PIDs (Parameter ID) and Save data for analysis.

This was originally written to help one person with his Ducato totally new to MES to start saving data. it is not an exhaustive manual nor intended to be. Tutorial to Measure specific Engine PIDs (Parameter ID) and Save data for analysis. Open...

www.fiatforum.com

 

[Dexron]

I'm also thinking about removing the cooler mesh and installing a filter, accessible from below, at the FAP outlet before the cooler.
Does anyone know of any removable LPEGR filter models?