57 plate 2.2TDCi 110hp
So i got the van in Feb 2020. Previous owner said it had an EGR valve replacement 6 months before (~Aug 19). By about September 2020 i had warning lights on - did a scan on my little £10 scanner and it gave me a P1409 code. Apparently this is "EGR Vacuum Regulator Solenoid Circuit Malfunction". I ignored this until Feb 2021 when the MOT was due and got the EGR replaced - no warning light.
6 months later the warning light pops up again and its the same code. I ignore it again and check the codes a few months later and get a P1103 code aswell - "Mass Airflow Sensor in Range But Higher Than Expected".
Now in September 2021, i had a cylinder misfire - got it towed to a mechanic and he said a fuel injector stopped working. I give the go ahead to do the repair and he calls me back saying that the glowplug snapped off and fell into the cylinder chamber - the head needs to come off to retrive it and clean out the cylinder chamber. They were also short staffed and ended up keeping my van from September until just before Christmas and charged me £1800 to get the head milled, new gasket fitted, fuel injectors replaced, and glowplugs replaced. All codes are cleared
I get the van back and after about a week i start getting the P1409, P1103, and a new P1402 code - P1402 = EGR Function Open. Again i ignore this and wipe the codes just before MOT and it passes before the warning light comes back.
I drive the van to Oxford (from Cardiff) for some job. Just outside of Oxford my van starts losing power and i don't know wtf is going on. I check my fuel gauge twice thinking i must be running out of fuel or something. On the second inspection i notice my temperature needle is trying to break its way out of the dash. Van is overheating. I pull over, check under the bonnet - water tank is empty. I fill up what i can with my drink of water and just manage to limp it to a petrol station. Whilst there i find the problem - the oil cooler hose has burst. I find myself a screwfix and bodge it back together with some PVC pipe and jubilee clips. It works well enough to get me back to Cardiff - although i made sure i kept the cabin in sauna conditions with all the heaters on.
But now i'm thinking that maybe the EGR valve isn't the problem. Why would 3 EGR valves break in under 3 years? Either i'm just unlucky or that isn't the source of the problem. Would a failed EGR cooler cause hoses to burst and EGR valves to repeatedly overheat without any warning lights about the cooler popping up?
The weird thing is that the guy in this thread:
viewtopic.php?f=5&t=108737
Had the EXACT same problem on a Van with the EXACT same year and EXACTLY same codes and hose bursting on him.
Any thoughts?