Forscan throttle position & underboost p0299

[Silverfoxbuilds]

Hi all, hope this is in the right place

Transit MK8 dually bus
2.2l 125ps

Camper conversion

I won’t bother you with the details of exactly what’s been going on for the last 18-24 months, but basically it’s never been quite right, many EMLs, many codes, multiple remaps, turbos, dpf flushes, EGRs, sensors and now I have a constant underboost. So for the last nine weeks It been a misery to drive unless you are ragging the balls off of it..

Specialist & Ford couldn’t find an issue more detail on that can be provided regarding this.

So the latest is……….
I’m having a strange read out on Forscan.

My EGR throttle position commanded is 0%

However, my EGR throttle plate measured is 100% (well 99.6%)

Cables have been Tested for continuity and for voltage and all seems well however my read out from Forscan scan seems to be backwards. I would presume that 0% means closed & 100% means open.

Just to clarify, we have a Mk8 custom for work and I have used forscan on this and as I expected both of the values commanded and measured are exactly the same 100%

Any light shed on this would be hugely appreciated as I am at my wits end, losing patience, money, and days/weeks/months off my life


TIA

Warren
(Silverfoxbuilds)

[dumper]

The control box on the turbo on mine went it was giving under and overboost coeds the variable veins on the turbo can also stick

[Silverfoxbuilds]

So brace yourselves, read on if you dare!

Fault(s)

(11/2/24)
-Returning home from Brighton van went in to limp mode and crawled in to sevices.
-Switched off engine and had to move van due to potential fine being in a garage for too long.
-Restarted van and moved 30m van had no lights on dash
-Green flag called and van had no codes shown so tested and drove home with out further fault
go really careful and check codes agin once back to find nothing stored.

Conditions
-van was on a hill A23 climbing, gradual loss of power and had to keep changing down gears in to 3rd, then limp.

——————————————————————————————————————————

(22/0324)
Nox sensor Bank 1
-cable has always been frayed since ownership so change both Nox sensors

——————————————————————————————————————————

(23/03/24)
I have had a rev flutter for the last 12 months at 1800rpm in almost all gears when using light throttle
The fault feels like the vehicle is pulsing the throttle, like a stutter or a misfire
-I’ve read that the EGR can cause this to removed it and cleaned and reinstalled but fault remained.

——————————————————————————————————————————

Easter weekend i had 6x EMLs over the course of 700 miles approx to North Wales

(30/03/24)
-1st P2563 turbocharger boost control position sensor a circuit range performance
-cycled key and fault disappeared
-2nd P2563 turbocharger boost control position sensor a circuit range performance
-cycled key and fault disappeared

(31/03/24)
-P2563 turbocharger boost control position sensor a circuit range performance
-went to halfords used EGR cleaner and fault cleared
cleared codes with reader and van drives fine

(01/04/24)
-P2209 sensor bank one
-P0825 gear lever push pull switch circuit shift anticipate
-presumed this was because i had sprayed cleaner in and it had upset values
-additive in full fresh tank of fuel

(02/04/24)
cleared codes with reader in morning and van drives fine but using as light a throttle as possible

(06/04/24)
Return home
-Van drives best so far of the week, and even was happy cruising along at 3/4 throttle around 60mph in 6th for 1hrs or so.
-that being said power is still poor and not particularly nippy.
-Now mph is at all time low of 16.5mpg
-We made it to Chievely A34 and we start to climb hill in fast moving traffic with no safe place pullover then comes engine service now.
Then two further faults that are unknow as the key cycle resets them and i have no log

General driving
-P0825 gear lever push pull switch circuit shift anticipate will randomly appear
van keeps going in to engine service now with code P2563 turbocharger boost control position sensor a circuit range performance van has almost no power when pulling up a gentle gradient.
Then tried to put van on to gentle grass slope, the van had no power and stalled, thought the wheels were spinning but it was just no power.

[Silverfoxbuilds]

Bit of history
I have a 4 acquaintances through the van with converted 2.2 minibuses, which have all had these faults or incredibly similar and all of these have had turbo actuator faults.

Last summer i had a blocked DPF in Austria and had the van ECU reset to latest firmware by ford Salzburg as they could not interrogate the ECU to force a regen. Then after multiple regens 5-6 and an supposed DPF flush and an examination of the vaporiser we were off and Drove home very slowly 20.1mpg with intermittent adblue fault, was faulty SCR injector so replaced and fault was cured.

since the summer the Van just drives sluggish, stalling on pull away is quite frequent with out a bit of additional throttle, but this is something start to get used to. I’m not expecting a race car but, this always feels “out of puff”. I’ve not got another minibus to compare with, but i daily drive a mk8 transit custom for work 130 bhp and that is on whole other level in comparison.


Mechanical work carried out
-Removed DPF and had it cleaned
-Checked vaporiser for functionality
-Replaced turbo oil feed pipe
-Replaced turbo with brand new recon unit from Falcon
Thought new turbo and actuator was potentially faulty and they were great and swapped the old unit for free and shipped next day. Fantastic service can recommend
-All new gaskets and hardware
-New genuine oil and filter


Turns out old turbo and actuator are perfectly fine

(Previous service, oil plus oil and fuel filter change was 1500-2000miles)


First start
Let van run to get up to temp all levels good and diag showing no DTCs

Test drive
-van pulls very well (huge improvement) in all gears and on all types of gradients, this last for approx 6-7 miles.
-first engine service now after work carried out
-DTC code shows P0299
-Seems to become more frequent now, every 3 miles or so.

conditions
when in low revs around 1500RPMs and I’m asked to engage 5th gear on dash, i reluctantly change to 5th and there is almost no power and the revs won’t climb. after a short period the van will hiccup if i haven’t quickly changed back down to 4th or even 3rd, and the engine service now warning will flash up.

- now this has become more frequent from 200m - 1mile intervals and will now happen mid to full throttle but mostly around the1500-2000rpm range in 3rd 4th 5th and 6th. but reset by cycling the key

-seems there is no boost in low revs and will struggle to pull away, almost like stalling off the line.
each time you can cycle the key and the code is wiped with no sign in the DTCs

-EGR valve removed and inspected to find carbon deposits in the plastic casing covering the solenoid so this must have been leaking through the valve seal
-Replaced EGR with new item

Reclean DPF and differential pressure was 60-70mbar at idle

Tests performed
-Pressure test on each pipe individually (all good)
-Pressure test intercooler (all good)
-smoke tested the system and no leaks found

-sent to ford independent garage and he found no fault, with all visible systems within correct parameters
he stated that “the live feed and the commanded feed for the turbo boost pressure were running along side each other within 1-2%, and would then literally disappear off my screen, there was no physical ‘drop’ in pressure? it was just as if the module running them was switching off?”

-i left with no labour charge but was suggested that although unlikely its possible the MAP sensor may be faulty and could be an intermitted fault, causing the values to vanish.

(27/04/24)
-I replaced the MAP and MAF with genuine parts for good measure but to no avail and I’m still having the same P0299 under boost code.

now I’m getting 13.5-14mpg

Take the van to STX tuning for a re-re-remap and limiter removal (3rd times a charm) and van is a different animal.
Replaced the intercooler for a new aftermarket mishimoto unit with custom pipework just incase… might as well every thing else is getting attention
Pressure tested all good

Removed the throttle plate and scrubbed clean. Then cleaned as much of the intake manifold as possible whilst in place . Relearnt the values by disconnecting the batts and letting idle for 1hr then drove as normal to further learn values


Drive went well but gears feel too tall for the engine and it’s always demanding im in the next gear. That being said it’s pulling well. Turbo is spooling hard and is loud up to around 3k then goes quiet, almost like the boost is being restricted up to this point, or screaming out a split hose then the van will surge in power around 3.5k .
It goes very well almost too well, and then “thump” in to limp and new code

P062B Internal control module fuel injector control performance

I have checked the fuel pump relay in the engine bay fuse box and the 7.5 amp fuse that feeds and it all is well.

MPG is roundabout 17.5 But we have been pulling hard in most gears to see if we can replicate this weird noisy
turbo lag thing up to 3K

I haven’t got a read out for my remap because I literally can’t find anyone in the south of the country that can get my van on a rolling road

and if you got this far, thank you for hanging on it’s been a journey……

So any information or anyone that you can point me in the direction of would be massively appreciated.

Thanks in advance for any responses

[dumper]

I’ve not had the problems you have had but had new turbo /add blue tank the dpf wouldn’t regen and went into limp mode at the same time fuel economy dropped from 31 mpg to 18 mpg it turned out to be the thermostat stuck open and not getting upto temperature .
I’ve been following O’Reilly Autos on YouTube and if I had the problems like you I’d be going to see him .

I’m a retired plant and transport fitter my last two jobs had dedicated auto electronics so I got left behind on the electrical side of the job so when it comes to electrical stuff I take it to Ford after the turbo was fitted the mpg dropped off to 18 took it back to Ford and when it was upto temperature and ticking over you could see the mpg readout fall in front of your eyes but they made nothing of it .
When the add blue tank went it went into my local Ford dealership they diagnosed it as only wanting a update this they did and it didn’t cure the problem but they couldn’t look at it for two weeks but I was booked to go on holiday in Ireland where it went Ito limp mode so took it to Ford dealership in the north they fit new tank and a force regen but goes back in regen in two days and that’s when they said it will not regenerate and it needs a thermostat after that it starts using add blue at a very high rate so two months later I’m back in Ireland I take it back in and they have it for a morning and said nothing wrong but after it’s back to normal usage my thought on this is they didn’t calibrate it my point on this ramble is the dealerships don’t understand them and they should do all they do is keep throwing parts and hope they solve the problem . as for my thermostat problem I should have changed it myself in hindsight and would not have had the dpf problem and that’s why if I get similar problems now I’m going to see O’Reilly autos.

[Silverfoxbuilds]

Hey dumper I’ve been following him for the last 12 months or so and even try to reach out to him but I presume he’s so busy with his YouTube stuff he never came back. He’s even posted about the amount he’s bothered 200 phone calls a day or something crazy like that.

We’ve even bought the launch DPF cleaning kit that he uses to properly flush the DPF to get it back down to correct values and make sure the things is running sweet.

Thanks for the info regarding the thermostat. I will go and check that now.

[Gavford]

Hello,

Just wondering if you had any luck solving this issue. I have a van with a similar issue. I have not gone down the road as far as you yet so any advice would be greatly appreciated. So far the boost pressure pipe and the EGR has been replaced. I will service the van tonight, but doubt that it could be anything related to that.

Thanks
Gavin

[knobby1]

Hello,

Just wondering if you had any luck solving this issue. I have a van with a similar issue. I have not gone down the road as far as you yet so any advice would be greatly appreciated. So far the boost pressure pipe and the EGR has been replaced. I will service the van tonight, but doubt that it could be anything related to that.

Thanks
Gavin

Welcome to the nuthouse.

What model Transit do you have..?? Assuming Mk7..?? Euro-4 or 5..??

Lord Knobrot

[WayneP34]

Did you get your issue sorted, I have a 2014 2.2 Custom with very similar issues. No power under 2k, frequent low boost faults and going into limp mode. Regening very frequently and the engine sounds like a London taxi. I have seen on forscan that when boost is low there is no signal from the throttle position sensor, as in no signal voltage. This then gives a throttle high reading which opens the egr valve to 60%. Then after driving for a time (this is not a constant period) the throttle position sensor reading will start to work. The egr valve then reponds accordingly and the van drives perfectly with full boost, good pick up below 2k and the engine is smooth and quiet. It will be like this for about 20 - 30 mins then the throttle position signal disappears again. Have replaced various items that have shown as faulty during my owning of the van and have checked all the earth points I can find. The only constant I have is the throttle position signal issue. Does any one have a ecu/pcm pin out and full electrical diagrams so that I can look at checking the wiring for breaks?