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

@deejays supurb work, it has needed doing for while. Originaly the information/ mis information came from Bosch UK via @Fredastaire but is compounded by poor database consistancy. The @MarcoWuerttemberger info concerning fuelling difference V28/V32 does not contradict maybe supports the info I was given by a "trusted " fiat pro dealership in that if you havent had a problem with V28 then keep it untill you do (the cynic in me says yes when its a problem it my pocket thats £10k lighter.). @serrow a repeat of what ive said previously,
dpf quality. One thing that ive said before and i know there will be no evidence to substantiate these thoughts (well not in the public domain) is that the ducato Dpf was of a new design and of a new production technology. I am not aware of the precise technology used (and no longer have contacts in Johnson Mathey) but with my knowledge of thick and thin film technolgies to coat ceramics i can sermise there could have been in the early days batch related production issues that could lead to cracking .
So what is causing the DPF to fail?
Possibly a combination of UPTO 3 issues
Dodgy? software
Injectors
Suspect batch of DPF

Software: one thing that is missing is detail on the temperature of regen with early versions and amount/timing of fuel injected to get a regen. If a difference between v28 and v32 also important. One thing relevant to this is is there more than 1 dodgy batch of dpf's eg late 18/19

@deejays a few questions
Have you had a blocked cooler/cracked dpf
have you the original c of c and know date from factory or any date eg from convertors date of export.
V24 too much to think you would have any MES data from that period or any regen info at all.

I'm trying to pin down dates of software Versions and manufacturing dates of problem vehicles.
The number of problem vehicles is quite low in comparrisson to Adblu but still too many possible time bombs ticking out there?
Thank you @theoneandonly . With so many Bosch part numbers, and vehicle manufacturer part numbers all overlapping with cross referencing for just one simple little part, it is no wonder that the entire industry is confused. That is why I asked for the actual transfer functions of each device - and just for the hell of it tested mine in vehicle to post calculate the impedance/temperature correlation. To answer your questions - I have so far had no issues with my vehicle and no evidence or symptoms of blocked cooler or cracked DPF - I periodically check with MES and exhaust wipes. I refer you to pages 51 through to 55 regarding the c of c and regen data as it has been covered off there when I first came across this thread. Cheers.
 
Thank you @theoneandonly . With so many Bosch part numbers, and vehicle manufacturer part numbers all overlapping with cross referencing for just one simple little part, it is no wonder that the entire industry is confused. That is why I asked for the actual transfer functions of each device - and just for the hell of it tested mine in vehicle to post calculate the impedance/temperature correlation. To answer your questions - I have so far had no issues with my vehicle and no evidence or symptoms of blocked cooler or cracked DPF - I periodically check with MES and exhaust wipes. I refer you to pages 51 through to 55 regarding the c of c and regen data as it has been covered off there when I first came across this thread. Cheers.
Thanks we are all here to help each other either sort a problem or prevent one, I did have a little search through your posts but missed what I needed it wasn't just a lazy ask.
 
Driven a good amount kilometers so far, no problems.Last temperature of regeneration with my modified version 28 was 592 degrees, if that helps
Thanks , did the remapper modify the regen process or just the idle low load injection
 
i don't think he modified the Regen process...he didn't tell me anything about this. He was lookin for the differences and remapped that.
Thanks again from that i'll infer there is no difference tween regen on V28 and V32, Probably allready modified in earlier versions
 
There is a new topic about the DPF problem. The author has pasted photos from MES. It has version V032. I am curious about the diagnosis.
 
There is a new topic about the DPF problem. The author has pasted photos from MES. It has version V032. I am curious about the diagnosis.
When I have confirmation of his run with template 4 i will advise the OP of the confirmed diagnosis and may advise him of the importance of this thread
 
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
 
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
Hi @Bevin , sounds like the beginnings of a blocked LPEGR cooler. From what I have observed, the LPEGR valve does not start opening until a few k's (warm-up) down the road. So what is likely happening is that when the LPEGR valve starts opening, and the cooler is already restricted, it will try and open so far that it will begin to strangle the incoming air via the air filter. This would result in reduced inlet manifold pressure and also the HPEGR will be forced to open fully. The result is as @Fredastaire has documented - a strangled engine. A quick first MES test would be to just graph the live data for the LPEGR desired and actual position, LPEGR temperature, and Engine temperature. I suspect that the fault will occur when the LPEGR valve is first opened.
 
Driven a good amount kilometers so far, no problems.Last temperature of regeneration with my modified version 28 was 592 degrees, if that helps
Hi @MarcoWuerttemberger @theoneandonly That regen of 592C seems low from what I have observed. What have you observed from the engine records you have @theoneandonly ? I have observed under V24 and V32 an average of 615C to 620C. Perhaps the regen has been remapped just slightly lower.
 
Hi @Bevin , sounds like the beginnings of a blocked LPEGR cooler. From what I have observed, the LPEGR valve does not start opening until a few k's (warm-up) down the road. So what is likely happening is that when the LPEGR valve starts opening, and the cooler is already restricted, it will try and open so far that it will begin to strangle the incoming air via the air filter. This would result in reduced inlet manifold pressure and also the HPEGR will be forced to open fully. The result is as @Fredastaire has documented - a strangled engine. A quick first MES test would be to just graph the live data for the LPEGR desired and actual position, LPEGR temperature, and Engine temperature. I suspect that the fault will occur when the LPEGR valve is first opened.
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.
 
Maybe V32 is just to optimize the fuel injection for
Hi @MarcoWuerttemberger @theoneandonly That regen of 592C seems low from what I have observed. What have you observed from the engine records you have @theoneandonly ? I have observed under V24 and V32 an average of 615C to 620C. Perhaps the regen has been remapped just slightly lower.
or it's because my DPF IS new and additional i fill Miller's in every fuel refill. So no need for higher temperatures to burn this **** Out of the DPF....Just guessing
 
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.
You mentioned that you wanted to know what triggered the fault after a small period of warm up. That is why I suggest to look at the actual opening of the LPEGR as the first time it opens will likely coincide with the fault code being triggered - if it does coincide it will confirm for you what is causing the trigger.
 
Maybe V32 is just to optimize the fuel injection for

or it's because my DPF IS new and additional i fill Miller's in every fuel refill. So no need for higher temperatures to burn this **** Out of the DPF....Just guessing
The burn temp of the DPF is sensed by the DPF Temperature Sensor and that signal is monitored by the ECU and the ECU will control the Post Injection to control the burn temp - so it is controlled by the ECU software. I don't think I'd stress too much - lower temp is probably good, so long as it is high enough to do the job. You will know that by observing the DPF Differential Pressure. It would be interesting to log the burn duration to see if it any longer than a documented higher burn temp For example, my average last burn temp and duration was 616.5 C and 381.8 S. The burn would be terminated in normal circumstances by the Differential Pressure of the DPF.
 
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