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

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

@kangexpress reference the LP EGR temperature sensor recently removed, is this a two wire sensor or are there multiple wires?
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im wondering if its possible to add a resistor to change the observed temperature to say 130 when its actually 100 degrees to see if the high temp would close down the egr opening value and stop the strangulation effect?
Yes, it certainly would be and very easy to do. You would need to monitor and measure the resistance of the existing sensor at various key temperatures, and then calculate the offset resistor value required. Whether it would require a parallel or series resistor for the offset would depend on whether the sensor is PTC or NTC. I know from some investigation I have been doing that the software will pick up any sensor that the design engineers determine to be either out of tolerance, or not in similar expected range to other sensors and either throw a code or substitute a value. Clever FIAT engineers - I am in awe of some of the things I find they have catered for. But a small shift may be OK.
 
Yes, it certainly would be and very easy to do. You would need to monitor and measure the resistance of the existing sensor at various key temperatures, and then calculate the offset resistor value required. Whether it would require a parallel or series resistor for the offset would depend on whether the sensor is PTC or NTC. I know from some investigation I have been doing that the software will pick up any sensor that the design engineers determine to be either out of tolerance, or not in similar expected range to other sensors and either throw a code or substitute a value. Clever FIAT engineers - I am in awe of some of the things I find they have catered for. But a small shift may be OK.
Yes i have done precisely this for a Mazda Bongo in the past, where a fan is switched on to cool engine (mid engine) if getting too hot (stuck idling on M1 traffic jams), to manual control by using a switch and resistor in parrallel.
Mazda not so tricky with thier ecu, as it also worked if you just added a short in parrallel (as confirmed by others).
As it was temperemental regards to temperature (and no real temperature gauge) i monitored temperature in 5 places with an arduino and simple lcd display.
 
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P0401 has appeared!!
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So back to square 1 where I was two years back. I've just started the engine from cold, within a few minutes the LP EGR opens and using Multiecuscan I can see the opening value going to 4.7.
Clearly indicates a blocked cooler. I've priced up a new DPF inc fitting at well over £5,000. I suspect I'll have just the cooler changed again as I still have a new unused one in stock, that hopefully should see the next two years....
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Maybe by then somebody will have come up with a working solution to stop the LP EGR strangling the turbo.
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If only reaching the LP EGR was possible I would still wish to try a new internal cam to stop the clean air butterfly from closing and just leave the cooler blocked.
 
P0401 has appeared!!
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So back to square 1 where I was two years back. I've just started the engine from cold, within a few minutes the LP EGR opens and using Multiecuscan I can see the opening value going to 4.7.
Clearly indicates a blocked cooler. I've priced up a new DPF inc fitting at well over £5,000. I suspect I'll have just the cooler changed again as I still have a new unused one in stock, that hopefully should see the next two years....
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Maybe by then somebody will have come up with a working solution to stop the LP EGR strangling the turbo.
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If only reaching the LP EGR was possible I would still wish to try a new internal cam to stop the clean air butterfly from closing and just leave the cooler blocked.
Sorry to hear it's back again, I'll be following in your footsteps in 2 years time then.
 
Today's been investigative graft. Van up on ramps I've undone the ring clamp at the joint between the DPF bottom outlet and the flexi pipe to the LP cooler. Blanked off the DPF outlet with a lead cap secured by a jubilee clip. I've a bottle of revive Turbo cleaner, I had in mind to spray up the flexi pipe with engine running and LP EGR open with the idea it might soften the carbon sludge at the tea strainer gauze of the cooler.
With the engine held at 2,000 revs there was almost zero suction so any idea of it pulling the spray mist to the gauze was a non starter. Multiecuscan showed the LP open at 4.7 (plus / minus a bit).
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We really need an electrical or mechanical mod to stop the LP EGR working.
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Any ideas welcomed
 
Today's been investigative graft. Van up on ramps I've undone the ring clamp at the joint between the DPF bottom outlet and the flexi pipe to the LP cooler. Blanked off the DPF outlet with a lead cap secured by a jubilee clip. I've a bottle of revive Turbo cleaner, I had in mind to spray up the flexi pipe with engine running and LP EGR open with the idea it might soften the carbon sludge at the tea strainer gauze of the cooler.
With the engine held at 2,000 revs there was almost zero suction so any idea of it pulling the spray mist to the gauze was a non starter. Multiecuscan showed the LP open at 4.7 (plus / minus a bit).
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We really need an electrical or mechanical mod to stop the LP EGR working.
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Any ideas welcomed
Hi , when I investigated my original LP cooler removed by fiat garage, I tried clearing soot with a air line off my compressor at 6 bar and removed most of the soot, obviously easy to do out of van ,but I did wonder if possible to push a rubber pipe from DPF port up to EGR cooler and blast with compressed air , but would it damage the LP valve?( With engine off is it shut ) Just thinking out loud ?
 
@Serrow225 thinking out loud- if the compressed air was fed in at the temp probe hole, and the flexi pipe detached at the DPF (as I have done today) could it blow the soot backwards out of the tea strainer the way it came in?
 
@Serrow225 thinking out loud- if the compressed air was fed in at the temp probe hole, and the flexi pipe detached at the DPF (as I have done today) could it blow the soot backwards out of the tea strainer the way it came in?
When I tried clearing LP I was holding a fine nozzle gun on mesh and soot was visible exiting on inlet side of LP , so I assume to have any success air would need to be concentrated close as possible to cooling matrix in LP cooler , I would guess air fired in not as close as possible would just disappear out the path of less resistance, the other thought I had was to work out volume of cooler and flexible pipe and fill up with a cleaner, obviously would need to seal pipe and pump in liquid, leaving for 24hrs , drain off leave to dry and then start engine, but again how close is LP valve to cooler ?
 
My concern is if you fill with cleaner fluid and any stays as puddles that on engine start there might be risk of some going through the turbo and hydraulic locking the engine.
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On the exit side of the cooler there is immediate a 90 degree bend. The temp probe is in this bend half way round.
 
My concern is if you fill with cleaner fluid and any stays as puddles that on engine start there might be risk of some going through the turbo and hydraulic locking the engine.
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On the exit side of the cooler there is immediate a 90 degree bend. The temp probe is in this bend half way round.
Ok , not worth it. Seems to be checkmate every which way?
 
This is the cooler. At the bottom end there is a mesh covered multi ribbed flexible pipe that goes to the DPF outlet. It's at the DPF extremity which I undid today.
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You can see how much water could be left inside at the bottom.
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Maybe blow hot air up inside? No idea how.
 

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I posted my first comment here: https://www.fiatforum.com/threads/f...d-esr-valve-issues.495442/page-2#post-4757693 before I was directed here.

Back story of issues and progress

1. In October 2023 I bought a 2019 plate Auto-Trail motorhome based on the 6 speed auto Fiat Ducato 2.3 JTD (F1AGL411B) 180BHP - None AdBlue, Twin EGR. 8.8m 5 tonne so she is a big girl!
2. Drove from the dealer to the site where we were staying. 20 miles.
3. After a few days, drove it to Scotland (200 miles away) to another site for the weekend. Mostly motorway driving.
4. Driving back down south, got 3 miles away from site and EML shows on Dash. No limp mode and it seems to drive ok.
5. Pulled into services and rang dealer who said to ring the warranty company (basically washed their hands of it - I must check with trading standards on this!)
6. Rang warranty company who said yes we can cover it if you get someone to look at it (Max cover £1000) - Drove the 200 miles back to site with EML on as it was a Sunday.
7. Got a mobile technician (RAC) to come out to site the next day and run a diagnostic (we were nowhere near a fiat professional garage) and clear the codes.
a. P0238 - Turbo pressure sensor A high input
b. P0401 - EGR Valve - insufficient flow detected
c. P0402 - EGR Valve - excessive flow detected
8. Sent the diagnostic report to warranty (Won't cover it as they thought it would cost more than they cover!)
9. Tried to book a fiat professional garage to look at it, but no dice, no-one had capacity until after Christmas. Drove the van for about 200 miles.
10. Rang another mobile mechanic (local to site) who ran a second (Snap-On) diagnostic which reported the following
a. Possible ECU Software update needed
b. EGR Valve fault needs replacing (No indication of which one)
c. Possible Map sensor needs replacing
d. Possible Maf sensor needs replacing
11. Mobile mechanic replaces EGR valve (High Pressure) - EML still on (I don't have a picture of the EGR valve) - He also removed a suspicious TDI tuning box that was connected all over the engine (This was not advertised as being fitted to the van when I bought it) - causing over fuelling. I now think this may have been added because the van has/had a turbo issue?
12. Mobile mechanic replaces Map/Maf sensor - EML still on
13. Mobile mechanic rings a Motorhome technician who says its the throttle body that needs replacing, so this is replaced also - EML light still on
14. Mobile mechanic suggests having a software update on the ECU. I bought my own OBD2 reader to be on the safe side.
15 The EML light is cleared by the diagnostic reader again (the above steps 11 to 15 took place almost every month or so over the last 8 months)
16. Took the van to Wales for a festival, EML light back on dash. I am able to read and clear using the cheap OBD2 reader and android software. Software reports the same as the snap-on (Except for the possible ECU update)
17. In the last 3 weeks, the P0401 and P0402 errors have disappeared and only the P0238 error is showing.
18. Boost pressure solenoid replaced with a genuine fiat part. The one installed looks OEM? - EML light still present, usually either before reaching temperature or just a couple of minutes after and while accellerating)
19. Total spend so far £900+ on parts and labour. Each time I checked the soot on the exhaust and at first there was a lot, but now there seems to be only a small amount (Not sure how much I should be getting as we have only been doing 30 miles max on each run)
20. Finally booked into a fiat professional garage for a diagnostic and a 5 year service (Belts, oil and filters) - 8 hours and £1720.19 later - Nothing found on the diagnostic as I had to clear the codes on the way to them because I was in limp mode (again). No software update of the ECU because Fiat had not issued a software update on this van (I did ask if they would do one and they said not unless Fiat told them to do one) - They also could not tell me which version of ECU i had.
They were able to tell me that the van had already had a new throttle body in 2019 (6 months after delvery from the manufacturer) -They say this is very unusual to have had 3 throttle bodies during the whole life of one of these base vehicles!

Checking my service book and it looks like maybe it had a dodgy service before I picked it up. There is a stamp in the book, but no documented work. The dealer has not replied to my request for information on what work was done when they had it serviced before sale. I am also suspecting the MOT might be dodgy too (It reports as fine on the gov web site when I check). - next MOT is due at end of September and I have a feeling it will fail! (Will report on that at a later date)

21. Physically checked all small rubber hoses (removed and blow tested for leaks [finger over one end, blow into other]. None found so far)
22. This morning, checked connectors on solenoid valve and connecting wiring - all seem ok - no corrosion. - Not driven it since. Next chance to see what happens is the coming bank holiday monday when we move sites again. This time it will be a big run down south (over 200 miles)

Fiat professional garage says they have had loads of pre and post 2021 plate fiat based ambulances in recently with limp mode issues, 6 speed and 9 speed autos, some with gear box issues, but most had limp mode. Their diagnostics and investigations indicate a blocked mainfold and it is taking up to 6 weeks to get parts! They suggested that if the EML light came on again it would need the manifold removing and cleaning?

I have yet to look under the van at the pipes connecting to the turbo, as I have read posts elsewhere that could point to a failed pipe somewhere else that is causing the P0238 error.

Guessing that the replacement HP EGR valve has allowed what ever crud was built up in the system to be burned off? - Gear changes are quite sluggish and 3rd to 4th happens at about 3000 revs. I have been trying to give it a thrashing to see if that would help. It may have done as those errors have now vanished.

At this stage I am struggling to understand why Fiat has not admitted there are issues, recalled these faulty engines and fixed them!

** I have since found a post from someone on another forum showing the fiat service description of P0238 error (Last image) so maybe the solenoid replacement is the way to go?

Thats about it for the time being. Apologies for the wordy post, but after 8 months, I have tried a lot of things and it does seem to be getting better, but there are obviously still issues.

Is anyone any closer to a definitive answer to this?

Thanks for reading my waffle!

Mike.
 

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@Fredastaire @theoneandonly , just getting your opinion on where we are now , we know if you have soot in tail pipe DPF has failed.
This will cause LP cooler to block and start p401p402 etc , so to cure problem we need to replace DPF and cooler . The DPF is specific to twin EGR model and some fail and some are ok !
We don't know what V32 addressed to regen cycle on DPF , and oddly comfortmatic vans fail more . So if we change DPF with a fiat item could it be new old stock and fail again within 10,000 miles as I imagine what fiat has in stock is what was left when production of twin EGR stopped .
To spend £5000 just to happen within a year would not be viable.
Any thoughts?
 
Fiat Ducato 2017 2.3 130 20'000 km
Campervan chassi

Ok new poster here, just read 18 pages from the start of this thread and the more reading done the more depressed I got, had to stop though since on holidays with my camper in Spain and have at least two of these codes that I know of P0238, P0236. First time this came on was a few days ago while in a town idling at standstill for about 10 minutes (around 36° ambient temperature) then going over some cobblestone the biip biip came, was weekend but managed to find a garage open they had big problems even connecting and looking for codes (used Bosch system here in Spain) they did manage to get the code erased but I got no information on what the code was. Few days later code back 😖 again managed to find a Bosch garage and had the camper there in for the day just to be told they can't fix it and take it to Fiat main garage! Few € lighter this morning I started reading this dreadful post. If someone could help me with two things: is there anyway to get the code reset ecu reset manually without using a reader? (I'm beating myself blue for not bringing mine in the first place and here in Spain Ive been trying to find one but proven Extremely hard!) Is there anything I could diy to help me get back home eventually dealing with all these other problems that would be greatly appreciated! I did bring a toolbox with some tools and pretty diy handy.

Driving style been different here on holiday in northern Spain with up and down a extra pressure placed on engine (rev and engine braking etc)

* Edit
It's manual, checked exhaust with wipe there is none that I can see, looked at the hoses and see no obvious cracks, engine was tuned a few years back by a reputable place in Sweden (<11000km ago)

Cheers
Ante
1000021003.jpg
 
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@Serrow225 your brief synopsis is near in correct.
The sooty exhaust denotes cracked failed DPF. The passage of soot reaches the strainer in the cooler and blocks it up. The LP EGR is there to mix exhaust and fresh air for the turbo to suck. The LP has two 'valves' one (flap), opens to allow exhaust in, the other (butterfly) closes the inlet of fresh air. The more the cooler blocks, the wider it opens the LP flap trying to get more dirty air, the more the flap opens then the butterfly closes more. Result? The turbo is strangled.
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The 'new' Fiat DPF part number is (I think) a later part number, if Fiat do the job they may give a 2 year warranty.
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If you have super injectors, latest software and new DPF you are probably safe.
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My thoughts are we need to be able to do something electrical or mechanical to stop the LP system from strangling the turbo. At the moment I don't know how to remove the LP without garage post hoist / remove DPF.
 
@Mike D Halliday and @aln1337 you both need Multiecuscan on a windows laptop, then converse with @theoneandonly , he will advise on which parameters to set up on a template then go for a run recording live data.
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This will identify problem areas.
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Ante, you possibly have an undamaged DPF if you haven't got soot in the exhaust, the tuning may have given you problems as you need V28 or V32 software (we think)
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Mike you will struggle to find any mechanic who has knowledge of twin EGR Ducatos. Please rely on Multiecuscan and theoneandonly to steer your future efforts.
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Fiat will solve your problems however likely cost is £8-11000 and give a two year guarantee.
 
Thanks for the swift response , so read that stopping the van when code and stop/start 99.9% of times get rid of limp is that accurate? Just need to get this yoke home from holidays before I can start do anything really then?, the V32 software when was this realised? I can ask the tuner what he changes if that could help others ?
 
@Mike D Halliday @aln1337
I'm sorry your in this prediciment and yes its rediculous that Fiat hasnt at least written some sensinsible diagnostic reports on this problem. I Find it rediculous (on another forum) that it was stated I know more about this problem than Fiat, totaly rediculous but I am prepared to talk about it. The collective certainly knows more than most Fiat Professional garages.
Mike I would take legal advice as to whether the van can be returned as to being fit for purpose as almost immeadeately the warrenty company identified a big bill.
Mike you need to identify if the exhaust is clean or sooty.
The easiest way to identify a blocked lpegr cooler (p0401 lpegr cooler syndrome) is to take live data from a 20min run (warm engine) and post results here. i will the create some graphs and analize your data. The best way to do this is with multiecuscan on a windows laptop (forget any ideas of apple or chromebook).
sorry must stop now i'm henpecked and must go shopping
 
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