MK7 2.4 RWD Fault codes P1402 & P1103

[richardp8315]

Hi All - I have been reading as much on here as possible re the above codes! - but would like any feedback on this well explored subject! I have a 2007/2008 motorhome on a transit 2.4 RWD chassis with 58,000km (36,000miles) . On a recent trip to the Alps the engine (MIL) light came on. Got to a Ford garage in Massif Central and they reset codes and said it could be the EGR valve or MAF sensor (I think as my French is not brilliant!). They said I could carry on as engine showed no signs of rough running or loss of power. 1000 km later, on our return the MIL light came back on. Just put an OBD2 tester on it and codes shown are P1402 (EGR monitoring orifice restricted) and P1103 (MAF sensor). Have taken MAF sensor off and it was very gummed up - cleaned it carefully with wd40. My question is - 1. do I reset fault codes and see what happens - 2. clean out pipe to inlet manifold which houses MAF sensor considering the amount of gunk on the sensor - 3. prepare for replacement of the EGR valve ???

Any feedback is very welcome!

[loot]

Egr is broken had 1 where the 2 pins on 1 if the gears was sheared off so the valve wasn't opening

[richardp8315]

Thank you for the reply - I thought as much - will order a new one - probably from UK (I live in France and they seem to be more expensive over here). Is it worth cleaning out the inlet tube where the MAF sensor is housed at the same time?

[loot]

It's always worth a strip down and inspection before spending money, not always practical tho, I'd clean the inlet out yes, will be full of crustys

[richardp8315]

Thank you for that - very helpful - Have ordered new EGR from TPUK via ebay.fr - much cheaper than local dealer here!!

Your help on here is much appreciated.

[Herts]

When you change the egr, take off the air vent above the engine.

You will need an 8mm and 10mm ratceh spanner.

Andy

[bazw]

how is the MAF covered in gunk? it should be seeing clean air from the air filter or could you be talkng about the MAP sensor where the inter cooler pipe joins the inlet manifold? 1 bolt to hold it not 2

[richardp8315]

Thanks for the tip regarding taking off the air vent Andy.

Yes I think my MAP and MAF are the other way round so my MAP sensor was gunked up

[bazw]

Did my EGR a few weeks ago, old one looked brand new but was not working. while I was on with it I did the glow plugs and took the inlet manifold off to cleabut it was ok. the room without the manifold helps and its only 9 bolts

oh btw it will make a funny noise when you turn off but this is just the valve cleaning itself and nothing to worry about ( poss a good indicator its bust if no gear noise when turning off)

[loot]

Mine never does it
I actually think it does it if it sees tiny fluctuations in the egr pot and possibly the maf.

[richardp8315]

Yes - I might think about taking the manifold off to get better access to the EGR to replace it as it looks difficult from above - have seen a thread on here suggesting getting at the bolts from underneath too but I would need to raise the front or have a pit so I will see what is practical.

The EGR on my van is still making that whirring/squeak when I turn the engine off, indicating that it is cleaning - possibly to no effect if the cogs/gears are broken!

[loot]

They are spring return so if it is sawing then it is possible that the cogs are OK, however there could be a fault in the pot, grub or valve, so the only way to find out is to strip it down.
Unfortunately, in my experience they wear out
I have actually got a franken egr that i made from 2
(I refer to the silver older type egr, not had a look at the black 1 yet)
I guess it's possible that the plunger in the head has stuck up which is making it think that it is stuck open.
There's tabs around the head that hold it on, you can bend them back to allow you to remove the head and see the cogs, motor etc, you can see the pot plunger and Poke it to see if it moves

[richardp8315]

Just been looking at engine/EGR in prep for replacement. My van is LHD so it seems easier to get at EGR valve than RHD (the air intake is not above this area and fuel filter is on left side of engine bay as you look at it. Seems I can get at all bolt heads so hopefully dismantling is kept to a minimum. Also seems my original EGR has a black top cover. The van chassis was built in Turkey with a commission date of March 2007 according to the Ford Etis site.

[loot]

You'll have the silver egr same as mine and the 1i refer to, the head is black plastic but the body is silver.
The later ones mostly seen on fwd are all black.
If you can reach the tabs you can gently prize them outwards and remove the retainer then the top which will reveal the gears, they just fall out tho and can be fiddly to refit, use white grease on then to make them stick in, the original grease may be dried or gone by now.
I removed my egr in situ without removing anything else except my intake. Did struggle a bit tho.

Just crack all 4 bolts so you know they will undo, some ppl have snapped bolt heads off or found them rusted and rounded off

[bazw]

I ended up under the van with a cut off grinder doing mine the other week. 1 10mm bolt would not turn , and head rounded off. ended up cutting through the alloy side to cut the bolt off.