Technical  Intermittent EDR error, clogged DPF

Currently reading:
Technical  Intermittent EDR error, clogged DPF

nfierst

New member
Joined
Jun 22, 2026
Messages
2
Points
26
Location
Bristol
Hey All,

Newbie to auto work here asking some basic questions to help me diagnose the issue. I've read a few threads on this and reasearched the mechanics at play, but can use advice and tips for next steps.

I have a 2006 Fiat Doblo 1.3 multijet (mk1/119). The DPF has clogged twice on me now, leading to poor power, and stalling out on hills, and more recently not being able to get up to 70 on the motorway. I had AA to check my car twice. The first time the EGR fault was thrown (I believe it was P0400), but the EGR actuated manually with the OBD tool. The second time the EGR fault was back, even though it still triggered fine manually.

I now have MultiECUScan and can actuate the EGR fine (I hear the clicking). I also ran a test at idle, and with the pedal pressed (while in neutral) to confrim the Air flow sensor more or less reduces when the EGR is open. I can't remember the specific PIDs I monotored here.

I then was curious so attempted to remove the EGR, and really struggled to access the bolts holding the EGR on. I have the solenoid off and can confirm the EGR actualtes very easily, so it doesn't appear to be an issue there. I may have stripped a couple bolts trying to get them off (will see later when my trolley jack arrives and I'm hoping i have a better view of the bolts from underneath).

My questions:
1. Do you havea ny ideas as to what could be causing the DPF to clog? Presumably something is happening with the EGR since it keeps throwing this error. My guess is that the pipe from the EGR back to the intake manifold is clogged.
2. What tips do you have to remove the EGR so I can inspect the piping? I spent ~5 hours on this over the weekend and didn't even get one bolt off.
3. The DPF blockage is calculated at 105%. I would like to trigger a manual regeneration, but this fails (I've read the threshold for the manual regeneration is 105%). Is the only option to take this in for professional cleaning?

*Edit: To add context, the most recent time this occurred was on a long trip with 4+ hours of motorway driving. Since I've had DPF issues in the past, I will regularly blast it on the motorway in 4th pushing the RPMs up to trigger the regeneration. It looks like the regeneration has been failing as the oil level is very high, with an oil change taking place just a week before this long trip.
 
Model
Fiat Doblo 1.3 Multijet (mk1,119)
Year
2006
Mileage
98000
Last edited:
P0400 es too much airflow vs desired (it's EGR not working ok or as you said EGR working but intake after EGR clogged). EGR errors could stop DPF regen.
Really 2 options:
1. dismount EGR and check intake + clean or change EGR
2. Forget dismount by now and try EGR intake cleaner additive (if it's not too clogged will fix it easy)
 
Okay, documenting progress here in case it's helpful and I also have new questions if anyone can help.

I ordered some longer torx bits where helped get the tools in the right place. I was able to take the EGR off with bolt remover tools after I stripped the hell out of them. The sad news is that the coolant hoses have fused to the EGR, and I didn't want to remove these completely to avoid having to replace them. I checked out the input and output of the EGR itself and I don't see any soot build up, and no evidance of issues at the EGR/cooler connection. At this point I'm assuming that the EGR isn't actually an issue, and the EGR fault was thrown due to the DPF being so heavily clogged up.

Next I plan to figure out what is causing the DPF regeneration to fail. I have a suspicion the engine thermostat might be faulty, as I've never seen the temp reading on the dash move beyond the mid mark. I plan to drive it around a bit to get some data with an ODB and see what I can capture.

However, I need to replace the bolts that mount the EGR. Does anyone have an idea where I can get replacements for these bolts? I've searched quite a bit but haven't found these for sale anywhere. Photo attached.


PXL_20260628_163637086.jpg
 
Back
Top