Help with Error codes mk7

[bobson6]

Well fiddled with the connector on the EGR and cleared the codes with FORscan and then took the van out for a run just keeping her in the lower gears and giving it a good clear out as the previous owner had not used the van for 3/4 month, and after 20 mins no light? i love chasing problems!

[bobson6]

Well, after a few weeks of a sweet running van, the idle issues returned last night when cold. Plugged in laptop and got p0404 - EGR control circuit range/performance again, even though new EGR fitted. Looking at the live data, the valve position at idle is 2.8mm, is this normal? should it be 0. I should add that until i revved the engine the valve was sat at 0mm and then when it dropped back to around 800 I got that reading.

Do you think its a duff EGR?

The only other this is the fuel light came on so I was thinking possibly some sh*t got sucked up out of the tank?

Also starting it this morning took two goes and when it did fire up chucked some white smoke out that stunk of diesel...

Once running and warm was fine, pulled well and no smoke.

[bobson6]

Right, ran the van for 5 mins with live feed showing egr map and mass along with revs.

Revs for first 3 mins were dropping by up to 50rpm to around 750 then back up to 800 peaking at 850.

Map was reading around 90kpa whole time

Egr would sit at 0mm until reved and would go to are 3mm and eventually drop back to 0mm at idle after about 30 seconds

I have no idea what is going on, like I have said egr is new. The p0404 code says actuator stuck open one min then closed the next... wiring looks fine and connector is clean.

Any ideas?

[bobson6]

Good few months of a perfect running van and it starts to idle funny again.

Error codes showing as

p0404 EGR control circuit range/performance
Actuator stuck open (the EGR valve has only done 1000miles)

and

p037D - Glow plug relay sense circuit
Signal invalid

Any ideas?

Van drives fine, pulls fine yet idles with up and down revs.

[loot]

A glow plug is shorting by the look of it, egr and connections need checking.

[bobson6]

Would it cause the van to suddenly lose power and engine management light to come on? Turned off restarted and was fine. Felt like It had lost all turbo?

[loot]

If the egr sticks open it can cause similar but if the glow plug shorts it can have a negative affect on the batteries like shorting the(possibly), i would fix the flow plugs or unplug the relay, you need to see the problem reoccur after clearing fault codes tho tbh

[bobson6]

Would you say even with it being a new egr it may be faulty? Wiring all looks grand and if it makes any difference when disconnected it runs exactly the same.

I have also got the water in fuel code?

[ake]

Would you say even with it being a new egr it may be faulty? Wiring all looks grand and if it makes any difference when disconnected it runs exactly the same.

I have also got the water in fuel code?

The egr wiring has been known to fail just at the plug, and would give intermittent faults like you are getting

[bobson6]

After hooking the laptop up last night. The error codes that were stored after the van going into limp mode along with the ones mentioned above were.

P062b - internal control module fuel injector control performance
P0089 - fuel pressure regulator performance - fluid leak or seal failure
P121c cylinder balance injector leaking

I cleared these and ran the van till hit with none of them coming back. I still have the other remaining faults.

Any suggestions? Ideas? I have checked all the wiring for egr and all seems fine. Would an age issue cause the above

[bobson6]

New MAP fitted
New MAF fitted
New EGR fitted
Wiring checked

Still get p0404 (sometimes stuck open and sometimes stuck closed yet live data shows movement)

Took van for spin, lost power after 10 mins, as if turbo had been connected. Can not see any problems with the pipes to it and from it. Got a error saying P0299 Turbo underboost and there is a slight high pitched whine after 2000rpm (after clearing this and doing a further 15 mins driving this did not reappear)

Occasionally getting cylindar miss balance error? this swaps between cylinder 2,3 and 4

I have previously fitted a new SRV, but did not do the PRV. I performed learns after fitting and all was successful


I really would appreciate any ideas as I am running out here. injectors? SRV gone (not sure if it was a genuine parts one)
Some figures from live view
RPM 800
Cylinder 1 -0.575
Cylinder 2 1.164
Cylinder 3 -0.682
Cylinder 4 0.099

Exhaust valve position 3.74
MAP 90.3kpa
MAF 6.86g/sec


Do these figures look correct?

[knobby1]

Overboost/underboost codes are usually/often EGR related. It's indeed possible for a new EGR to be faulty...not unheard of.

MAF, MAP and the rail temp/pressure sensors rarely fail.

I'd be tempted to do an injector leak-off test, will give a fair idea of injector health...

Lord Knobrot

[bobson6]

tried a new EGR today, the last one was on for around 1000miles

I have got myself a kit for doing a leak off test, just unsure on how to disconnect the leak off pipes on the tops of the injectors???
Do they unclip straight off the tops?

[knobby1]

tried a new EGR today, the last one was on for around 1000miles

I have got myself a kit for doing a leak off test, just unsure on how to disconnect the leak off pipes on the tops of the injectors???
Do they unclip straight off the tops?

If two "new" EGR's fail...I'd be looking at the loom or plug connections for faults etc...

The little "clips" should just pull off, but be careful of the clips, little "O" rings and plastic tubes....age may have made them a tad "brittle".

Leak-off test is done at idle/tickover for 4 mins...Ford limits are 25-40ml for each injector.

Lord Knobrot

[bobson6]

Are there common places that cause problems on the wiring? I have checked the connector and used contact cleaner on it. And stripped back on the split for map sensor. The rest of the loom looks perfect.

Feels like I'm going around in circles. Will try to do leak off test later. But would a fault in her circuit cause the other faults to come up?

Last night it lost power to begin with then when restarted it was fine