EGR Stuck Transit Mk7 2.2 TDCI FWD 2006

[Simonmate2010]

Hi all!

i have a 2006 Mk7 TDCI that keeps springing up an EGR fault. I have put a brand new EGR (OEM) in and its still showing the same fault. 'EGR stuck open'

Also its showing P0404 - i have driven the van around but every time it just keeps throwing up the emissions light after clearing the code.

Anyone got any idea? maybe an electrical issue? i dont fancy spending money on another OEM EGR to check...

Thanks in advance.

[knobby1]

Hi all!

i have a 2006 Mk7 TDCI that keeps springing up an EGR fault. I have put a brand new EGR (OEM) in and its still showing the same fault. 'EGR stuck open'

Also its showing P0404 - i have driven the van around but every time it just keeps throwing up the emissions light after clearing the code.

Anyone got any idea? maybe an electrical issue? i dont fancy spending money on another OEM EGR to check...

Thanks in advance.

Wiring to/from the EGR valve not happy..?? Wiring to the MAP OR MAF sensors not happy..??

Lord Knobrot

[Simonmate2010]

Is there a trick to test the plugs?

I am a complete noob with this sort of stuff. I assume voltage meter?

I think the MAF sensor wiring might be an issue but i have no way of testing it?

Thanks

[DanMK7uk]

Blank and map out of pcm

[DanMK7uk]

Is there a trick to test the plugs?

I am a complete noob with this sort of stuff. I assume voltage meter?

I think the MAF sensor wiring might be an issue but i have no way of testing it?

Thanks

Visually check plug and connectors and harness for a start.

[metalworker0]

MAF is monitoring the whole intake air quantity and flow , so if EGR is stuck open, and leaking air down the exhaust. it will be reporting to the PCM the values, since the values are wrong, compaired to what it should be, because of loss of pressure and flow, PCM will think MAF is wrong ..when all its doing is its job.
Pull the EGR apart and clean the sticking valve.

all the best.mark

[Simonmate2010]

Thanks to all!

I will check all plugs.

I have noticed the screw that holds the MAP has snapped off so the MAP sensor must be moving around! that may be it!

appreciate all your time in responding!

[Simonmate2010]

Could someone help me on this?

I have just cut out the MAF wiring and soldered on a new plug - i tihnk my soldering was dodgy now the code is coming up for erratic wiring. I am still getting P0404.

Does anyone know what the 2 x black wires are for?

[andz327]

Have you put the correct colours in the correct positions in the plug
And there's not black wires on original part then don't worry about them, check for wire breakage as far into the loom as possible, when they get auld they get brittle

Sent from my SM-G990B using Tapatalk

[Simonmate2010]

Have you put the correct colours in the correct positions in the plug
And there's not black wires on original part then don't worry about them, check for wire breakage as far into the loom as possible, when they get auld they get brittle

Sent from my SM-G990B using Tapatalk

Do you know what these wires could have been for? i am worried that if the previous owner has a EGR delete or a remap then the PCM will need to be reprogrammed?

[metalworker0]

Does this site give you any clues

https://strperformance.com/en/ford-egr- ... -tdci.html

wiring diagram is blurred hard to read and understand their terminology as i think its a translation from french ..their wires are not black they are blue and red

https://strperformance.com/62229-large_ ... 2-tdci.jpg

i could be wrong, think its fitted with and egr delete kit and those wires go to a module or something else .

all the best.mark

[Simonmate2010]

Does this site give you any clues

https://strperformance.com/en/ford-egr- ... -tdci.html

wiring diagram is blurred hard to read and understand their terminology as i think its a translation from french ..their wires are not black they are blue and red

https://strperformance.com/62229-large_ ... 2-tdci.jpg

i could be wrong, think its fitted with and egr delete kit and those wires go to a module or something else .

all the best.mark

That would be the issue! thank you so much! this explains so much about my vans history - the previous engine had to be swapped due to an issue on the cylinder and injector inbalance. it must have been a dodgy kit installed.

You sir have just solved about 3 years of headache! THANK YOU SO MUCH!

i will have a look in to the KAM reset or PCM update to check to see if any learned values are now affecting the EGR... i think the EGR must have been running on this for years so much have messed up the PCM possibly?

[andz327]

Your plug has 5 wires not 4 as in cc pic

Sent from my SM-G990B using Tapatalk

[metalworker0]

this may help you better - still in french ...but at least its clearer

https://i.ebayimg.com/images/g/s-gAAOSw ... -l960.webp

from ebay listing

https://www.ebay.co.uk/itm/326473299941?

all the best.mark