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.