mk4 2.5 turbo has a variety of issues

[davey068]

Hi, I've a 1999 transit mk4 2.5lt turbo motorhome, called Uriah (after the group the mature ones will know why) It lost power and stalled when going round a bend (which is where I'm headed at the moment) eml on. started ok eml off then fast idle, stopped engine restarted fast erratic idle very lumpy, garage said it was EGR fault, taken off and found it blocked and blanked off. cleaned, refitted and rescanned same fault. New EGR fitted as soon as throttle touched eml on. Garage baffled think it might be a sensor.
have so far changed
EGR control valve
intake manifold pressure sensor
refitted original EGR
Removed blanking plate
changed wastegate actuator
replaced ecu and scanned same faults showed, refitted original ecu
I've checked all hoses to the sensors for splits holes and am waiting for TPS to arrive

codes from the scan are
P0105 BAP(Barometric pressure) sensor circuit
P0400 EGR system flow malfunction
P0401 EGR insufficient flow detected
P0402 EGR excessive flow detected at idle
P1108 Dual Alternator battery lamp circuit
P1109 Intake air temperature 2 circuit intermittent
P1171 Rotor sensor
P1173 02S- inversion
P1174 Cam Sensor
P1177 Synchronization
P1190 Calibration resistor
P1192 V External
P1194ECM or PCM A/D (analog to digital) Converter
P1258 Pedal Correlation PDS1 and PDS2
P1300 Boost calibration fault
P1301 Boost calibration high
P1302 Boost calibration low
P1402 EGR Position sensor system

the codes don't seem to make sense, a few 'mechanics' have looked at them and scratched their heads. One suggested the turbo might be faulty, I removed the inlet pipe and there is a slight movement on the turbo but am told thats because the oil had not been pumped through yet?
I'm trying a new tps sensor as the engine will happily tick over for awhile, it is only when the throttle pedal is pressed that the eml will come on.
The exhaust is clear at idle light grey when accelerating occasionally pumps out black smoke there is a smell of unburnt diesel when revving up
any suggestions would gratefully received or help to push it into a deep lake
I need it running asap as the wife’s nagging is driving mad even got one of my dogs at it
probably missed some info
Thanks Dave

[metalworker0]

That many faults means one thing only

The 12 volt electrics are not up to it - electronics require the 12 volt or transformed voltages from the 12 volt
You need to check the battery condition,you need to check all grounds, battery posts, the thick red from the alternator. unscrew everything , wire brush etc , you need to check if grounds are missing also .. particularly to the engine grounds.

you need what is called what is called the BEMM (body and equipment mounting manual)manual that lists where they are. which after a few searches , i cant find


all the best.mark

[davey068]

Thanks Mark
Have done as you suggested and checked and cleaned all earth/ground points I could find. Battery is only about 2yr old looks ok on outside, cleaned the posts and connectors.Checked voltage and it was reading 12.4v.
Checked cable at alternator, cleaned and brushed post, refitted cable. checked output from alternator pushing 14.8v. let it idle about 40min while checking for any missed ground points having coffee etc.
Turned engine off checked battery voltage, took about 5min to drop down to 12.3v. nothing running
Used forscan got same codes still unable to clear them

Tried looking for the manual no luck so far.
Only thing I have found is both fuses to the leisure battery have blown, I don't use it as I've got solar power for the rest of the motorhome on a separate circuit

Dave

[metalworker0]

Next is the PCM plug
.. on some later transits this can get wet from windscreen leaks, don't know about yours ... 27 years old, may have rot under the windscreen surround,you may find the pins corroded ,.. or even have water inside the PCM -- sorry i don't know where its located on your mk5

all i can find is 2000 year of mk6 - same lay out, i dont know =- tells where the fuse boxes are ..not the modules .. which are in the BEMM the PCM is probably the unit with most wires going into it, google AI tells me BEMMs did not exist before 2000 IN digital form


mk6 owners manual

https://www.fordservicecontent.com/Ford ... ldtype=web

Anyone reading this who has the BEMM please upload it to somewhere for this chap


most likely place, in the glove box of one, in the breakers yard

what i did find - wiring manual
https://www.ebay.co.uk/itm/147262015846?


all the best.mark

[V184]

Hi, I've a 1999 transit mk4 2.5lt turbo motorhome, called Uriah (after the group the mature ones will know why) It lost power and stalled when going round a bend (which is where I'm headed at the moment) eml on. started ok eml off then fast idle, stopped engine restarted fast erratic idle very lumpy, garage said it was EGR fault, taken off and found it blocked and blanked off. cleaned, refitted and rescanned same fault. New EGR fitted as soon as throttle touched eml on. Garage baffled think it might be a sensor.
have so far changed
EGR control valve
intake manifold pressure sensor
refitted original EGR
Removed blanking plate
changed wastegate actuator
replaced ecu and scanned same faults showed, refitted original ecu
I've checked all hoses to the sensors for splits holes and am waiting for TPS to arrive

codes from the scan are
P0105 BAP(Barometric pressure) sensor circuit
P0400 EGR system flow malfunction
P0401 EGR insufficient flow detected
P0402 EGR excessive flow detected at idle
P1108 Dual Alternator battery lamp circuit
P1109 Intake air temperature 2 circuit intermittent
P1171 Rotor sensor
P1173 02S- inversion
P1174 Cam Sensor
P1177 Synchronization
P1190 Calibration resistor
P1192 V External
P1194ECM or PCM A/D (analog to digital) Converter
P1258 Pedal Correlation PDS1 and PDS2
P1300 Boost calibration fault
P1301 Boost calibration high
P1302 Boost calibration low
P1402 EGR Position sensor system

the codes don't seem to make sense, a few 'mechanics' have looked at them and scratched their heads. One suggested the turbo might be faulty, I removed the inlet pipe and there is a slight movement on the turbo but am told thats because the oil had not been pumped through yet?
I'm trying a new tps sensor as the engine will happily tick over for awhile, it is only when the throttle pedal is pressed that the eml will come on.
The exhaust is clear at idle light grey when accelerating occasionally pumps out black smoke there is a smell of unburnt diesel when revving up
any suggestions would gratefully received or help to push it into a deep lake
I need it running asap as the wife’s nagging is driving mad even got one of my dogs at it
probably missed some info
Thanks Dave

Clear all the codes then run it see what it brings up then , theres a few injection pump codes amongst them

[Fo-Banshee]

Not a manual but used it often to help. https://partsouq.com/en/catalog/genuine ... DVLYK14689

[davey068]

Tried clearing codes but they won't go, just been through all connections again, checked all earth points could see still no change decided to check connection on injector pump and found this?
20260618_183310.jpg
20260618_183739.jpg
it doesn't look too healthy, can't work out if it is some sort of grease

[metalworker0]

That's a type of corrosion called verdigris, happens on brass , copper, bronze etc yellow metals when exposed to water and salt.
some electrical cleaners clean it off

all the best.mark

[cherniy_chack]

I think the main error is this: "P1171 Rotor Sensor".