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

[MarcoWuerttemberger]

@MarcoWuerttemberger I just spent hours to find guys with the same problem.
Our Fiat Ducato 180 is in Garage since Sept. 2024. They didn’t found the problem yet
They have already replaced the EGR, the MAP sensor and the air filter.

May can I ask which garage you went to or if we could perhaps talk on the phone? I'm really desperate, the garage has been telling us to sell it for months.
We’re from the south of Germany (Freiburg), near Switzerland and France. I would drive anywhere for our Fiat. We rebuilt it for 1 1/2 years for our needs.
It would be really great if you can may help us out.
Thank you in advance und Grüße aus Freiburg

du hast übrigens ne PM

 

[theoneandonly]

Greetings learned peoples,
I have been following along and using your methods to test my 2016 Euro6 burstner (B1) which has a clear exhaust and no faults against my friend's identical vehicle (B2) bought at the same time in UK and exported to NZ after travelling in Europe for a few months.
B2 has a reproducible fault (P0401 and P0238) on warmup about 3 km down the road which if cleared once warm, the vehicle runs well with good acceleration and good MPG but a sooty exhaust. So far B2 has has the MAP sensor replaced like for like with the 028 part and is about to make a decision on a next expensive step.
My question is why does the fault occur only on warmup and what should I look for in the OBD readings to show what triggers the fault?
One thought I had was that when cold the LPEGR cooler blocks up quickly with wet soot but as it warms more gases get through to allow the engine to run without fault.
Cheers Bevin

I simple terms the Twin egr lpegr cooler syndrome is covered in 2 guides. there is also one on how the twin egr system works.

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

The second guide (refered to in above) details why the p0401 is thrown when its nothing to do with the hpegr valve

 

[theoneandonly]

I am trying to answer a few questions about which models are more suseptible to the blocked cooler syndrome. I have too many blanks to be statisticaly happy about certain statements so this question is out to all those that have had a blocked cooler not just those in the following list. pleASE REPLY TO THIS THREAD OR PM me, either will do.

@aschoots ,@Dave Ducato , @CheeseMonster , @jansla , @Niko94 , @Poachersmoon, @RR58, @Serrow225 , @theGman , @athoirs , @Cariou , @chumleywarner ,@Mbackiel , @Mike D Halliday , @Paravan , @phaphanou , @rolopolo , @Shugzter ,@Sillystu84 , @steve clark , @steve298 , @tango Quebec

comfortmatic / Manual Software version at start /at end. Engine 130,150,180 date/ year preferably from factory (c of c) or convertor or reg / Country
example
c / m v24 (or?) / v32 130 2016 coc / GB D NZ etc
Mine

 

[deejays]

I am trying to answer a few questions about which models are more suseptible to the blocked cooler syndrome. I have too many blanks to be statisticaly happy about certain statements so this question is out to all those that have had a blocked cooler not just those in the following list. pleASE REPLY TO THIS THREAD OR PM me, either will do.

@aschoots ,@Dave Ducato , @CheeseMonster , @jansla , @Niko94 , @Poachersmoon, @RR58, @Serrow225 , @theGman , @athoirs , @Cariou , @chumleywarner ,@Mbackiel , @Mike D Halliday , @Paravan , @phaphanou , @rolopolo , @Shugzter ,@Sillystu84 , @steve clark , @steve298 , @tango Quebec

comfortmatic / Manual Software version at start /at end. Engine 130,150,180 date/ year preferably from factory (c of c) or convertor or reg / Country
example
c / m v24 (or?) / v32 130 2016 coc / GB D NZ etc
Mine

@theoneandonly
A good idea to collate more user data. Can I offer my two bobs worth? I know of another three dual EGR Ducatos in Australia. One is identical to mine (also similar manufacture date) and from the owner’s memory, has had slight traces of soot in the exhaust for most of its life (unfortunately indicating a likely cracked DPF) – but not yet displaying any issues and runs very well. It has done around 70,000km. Another vehicle – which originally was a rental vehicle before private purchase, rolled out of the factory in early 2017. It has done around 100,000km, has a very clean exhaust and runs very well. It is a 180 motor. It is still running the original factory SW V23. The other vehicle, also a 180 motor – not sure of the manufacture date has also no issues and a clean exhaust. The common thing with two of the above and mine, with no issues and clean exhaust is they are vehicles that are only used for holidays and are not what you would call a daily driver. As such they are rarely exposed to short duration trips and continuous start/stop traffic in heavy built-up areas. The one vehicle with slight sooty exhaust is used for every day living as well as holidays. All are Comfortmatics. The one nagging thing is the one that has a sooty exhaust may have had a FIAT PRO forced regen carried out!

Do you think it may shed some more light on the issue if we could collect the following data from all owners and importantly including those with no issues if happy to do so – it may provide more insight and a possible contributor to the issue?

The current data below is from my vehicle – Comfortmatic, V24 from factory then V32 mid-2024, 150, Factory date Nov 2017, Adria build. It has no issues.