Technical Fait Ducato - check engine issue, DPF and ESR valve issues

[Mike D Halliday]

Was this issue ever resolved? I have a 2019 Auto-Trail Frontier Comanche with 2.3L Mk4 (295) Ducato Maxi with 6 speed autobox. It has 32000 miles from new and since we bought it in October 2023 we have ECU light on the dash numerous times. So far I have had a new EGR valve, MAP Sensor, MAF Sensor and Throttle Body fitted. All of the original replaced components were caked with soot! I also found a TDI tuning box fitted, so that was removed completely. The light has been cleared but returns after between 2 and 5 miles or quick acceleration, with limp mode following. If I clear the code again, full power is restored and the light does not come on again until the van has gone completely cold. It has been suggested that this is now an ECU software issue or a cable short, but my ODB2 reader does not show me the current version in the ecu and all the cables look to be fine. The closest Fiat Professional garage is over 25 miles away in wales but as we are in the van all the time it is difficult to get it to any garage. What else can be replaced or could it be just a software issue?

 

[Fredastaire]

First I make the assumption that you do not have an Adblue model. If it's only got one filler cap for diesel then you have a twin EGR model.
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At this stage you haven't given any fault codes.
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Please may I refer you to the references on page 1 if this post which refer you to the main ongoing post which is now in over 50 pages. I started that post and still have my Ducato.
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There is also reference to you needing Multiecuscan software coupled with a windows laptop. In conjunction with member @theoneandonly he can tell you what to look for.
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For the twin EGR model it's a well known well documented problem. I would suggest at the moment you investigate further and keep away from a main dealer. They have standard notes and will easily furnish you with a bill of £7-10 thousand.
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Until we know which version van you have plus fault codes we are guessing. We can help you on the main 50 page forum post if yours is one of ours.
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Kind regards

 

[Mike D Halliday]

First I make the assumption that you do not have an Adblue model. If it's only got one filler cap for diesel then you have a twin EGR model.
.
At this stage you haven't given any fault codes.
.
Please may I refer you to the references on page 1 if this post which refer you to the main ongoing post which is now in over 50 pages. I started that post and still have my Ducato.
.
There is also reference to you needing Multiecuscan software coupled with a windows laptop. In conjunction with member @theoneandonly he can tell you what to look for.
.
For the twin EGR model it's a well known well documented problem. I would suggest at the moment you investigate further and keep away from a main dealer. They have standard notes and will easily furnish you with a bill of £7-10 thousand.
.
Until we know which version van you have plus fault codes we are guessing. We can help you on the main 50 page forum post if yours is one of ours.
.
Kind regards

According to Fiat Professional online portal the vin returns a Model: 295, "295 CANH1J1Y 2300", none adblue.

Codes from Android "Car Scanner" software and Bluetooth ODB adapter.

Car Scanner ELM OBD2
DTC report
Selected brand: Fiat
VIN: ZFA***************

============1==============
P0238
Raw code: 0238
ECU: OBD-II
Status: Confirmed
Turbocharger (TC) boost pressure sensor A/supercharger (SC) boost pressure sensor A - high input
turbo pressure - low pressure,

============2==============
P0401
Raw code: 0401
ECU: OBD-II
Status: Pending
Exhaust gas recirculation (EGR) system - insufficient flow detected
EGR air control negative drift - high air quantity,

============3==============
P0238
Raw code: 0238
ECU: OBD-II
Status: Confirmed
Turbocharger (TC) boost pressure sensor A/supercharger (SC) boost pressure sensor A - high input
turbo pressure - low pressure,

============4==============
P0401
Raw code: 0401
ECU: OBD-II
Status: Pending
Exhaust gas recirculation (EGR) system - insufficient flow detected
EGR air control negative drift - high air quantity,


My mobile mechanic chap who has replaced the EGR, MAP/MAF and Throttle Body used a professional Snap-On diagnostic reader and one of its recommended solutions was ECU update, the other being short circuit. Replacement of parts was another solution on the list.

 

[NeilDD]

Hi Mike,
The first 3 digits of the Vin after the ZFA give the model number.
If you can supply this it will help eg ZFA250 is a model 250 etc

 

[Fredastaire]

As expected..
It's highly likely your LP EGR cooler is blocked, (minimum).
You need Multiecuscan connected and check the opening of the LP EGR and the LP EGR temperature, both whilst driving and collecting data as a csv file.
@theoneandonly will be able to display the data as graphs.
Can you wipe out the inside of the silencer tailpipe. Is it spotless or sooty?.
Everybody changes the HP EGR because the fault code reader tells them to. It's a complete red herring.
Do please join us on the main 50 page post.

 

[Mike D Halliday]

Hi Mike,
The first 3 digits of the Vin after the ZFA give the model number.
If you can supply this it will help eg ZFA250 is a model 250 etc

Yes it is zfa250000 etc

 

[Mike D Halliday]

As expected..
It's highly likely your LP EGR cooler is blocked, (minimum).
You need Multiecuscan connected and check the opening of the LP EGR and the LP EGR temperature, both whilst driving and collecting data as a csv file.
@theoneandonly will be able to display the data as graphs.
Can you wipe out the inside of the silencer tailpipe. Is it spotless or sooty?.
Everybody changes the HP EGR because the fault code reader tells them to. It's a complete red herring.
Do please join us on the main 50 page post.

The silencer has a small amount of soot, but not excessive. If the lp egr cooler is blocked, is it a big job to clean?

 

[Fredastaire]

The silencer has a small amount of soot, but not excessive. If the lp egr cooler is blocked, is it a big job to clean?

Cleaning it is easy, getting to it is MEGA.
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It's vehicle on h ramp, dismantle lower suspension, re move subframe, detach power steering, detach DPF.
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It's all detailed I the main forum 50 page post.
You also need ECU software V32 for comfortmatic..(V28 we think is for manual gearbox, most times).
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Please buy Multiecuscan, engage the help of @theoneandonly and we will help you clarify if my suspicions are right or wrong.
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Regarding earlier comments, the zfa doesn't help, twin EGR Ducatos are x290 yet the stamped vin number will read 250.
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Do please join us on the main post on here.

 

[theoneandonly]

53 pages is a bit of a trawl the following is a simplified version.

Ducato twin EGR Engine with P0401 Code (2016 to 2019)

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

Here you will find a list of my guides on what is required to use multiecuscan on a laptop and how to save the data to a csv file. If you post it here i will then analize it

Guides by theoneandonly

www.fiatforum.com

It is highly likely you have a blocked lpegrcooler. But this can only be confirmed with live data. The Fiat time for replacing it is 8 hours. The freeze frame data for the p0401 code will be usefull.