Coolant needle on max/loss of power & cuts out...

[MXG9]

Hi all.

I'm hoping someone can help me with my transit connect (1.8 TDDI 2005)

When driving from cold, after about 5/6 mins the coolant gauge gradually moves to maximum, after about 20/30 seconds it limits the power and cuts out (guessing this is the safety cut off)
Its not actually getting hot or overheating, i took coolant cap off, no hissing/pressure. Again probably not warm enough to.
Oil is all good along with coolant.
I replaced thermostat, still having the same issue. Fan kicked in about 3 mins after starting it up to try and bleed coolant (dont know if this normal/coolant needle still on max)
When turning the van off or after it cuts out, i give it about 30 seconds before turning it back on, fires straight up, needle sits half way then after 10 seconds goes back to max.

I plugged in OBD reader and getting P0409/P0404 (EGR control circuit range/performance) & (EGR gas recirculation sensor A)
would egr cause both the symptoms I'm having? Would a poor ground cause faulty resistance readings? What would you guys replace next or look for.

My next thing to replace was going to be the temp sensor but running out of ideas now.

I purchased the van last week, drove it back from wolverhampton about 1hour 20 mins drive and didn't miss a beat was perfectly fine coolant needle stayed in the centre, parked it up for 3/4 days and drove it then had my issue with it.
It had been sat for a little while before i bought it as brakes were seized, but don't think that would have anything to do with it.

Any help would be appreciated.

Thanks:)

[metalworker0]

I think the coolant and the EGR are two separate issues ..but the loss of power maybe EGR stuck open. or vacuum pipe trouble.

you need a code reader to know exactly

Don't know which EGR valves they had on in this period on yours ..some had modern motorised ones ..some had old fashioned ones ...that no one has ever talked about here ...only talked about swapping the complete unit ..as they say are un- serviceable i suspect yours is such a unit ....i have such on mine ..as that is 2006 and tddi

looks like this ......I've not messed with mine ...but would be sure to tell everyone here, how to go about fixing this unit if it failed. so lost for answer

So cant ad anything ,...as its the "unknown" to me at this point in time

(note to me nothing is un-serviceable, and there is a way around everything, I would take the un- serviceability statement as a challenge)

Anyway old Fashioned one looks like this ...note the thing at the top of the picture that controls it

https://bparts-eu.s3-eu-west-1.amazonaw ... t3liuf.jpg

or this

https://cdn.proxyparts.com/parts/101331 ... a45424.jpg

but not this ...this is the newer type that is FULLY serviceable

https://cdn.proxyparts.com/parts/100109 ... 96603f.jpg



And its worth checking the vacuum pipes and wiring ..that's where i would start
note vacuum pipes are also linked to turbo actuator ..i think ...so loss of vacuum could effect that also ..so you'd be well down on power!

Temperature gauge

The temperature gauge trouble could be the temperature sensor or the wiring

This video i think may have details and tips...also this engine has the old type of EGR sorry only one i could find ..and looks a bit, shall we say Del boy .. ///mmmmmmmmmmmmm well lets say, its all i could find.

https://www.youtube.com/watch?v=FcyalwFcxWM

all the best.mark

[MXG9]

Thanks mark,

Mine is the old EGR one (first 2 pics you sent me)
No idea how easy they are to swap out, but I’ll check the vac pipes for leaks. If not then I’ll get a new unit, but I think the main concern is the temp needle sitting at max as it’s shutting engine off after 5 mins with fan on. So I think I’ll try new temp sensor first and go from there.

Does it have 2 temp sensors on these engines? Cylinder temp and coolant temp sensor? Or just the one?

Thanks

[metalworker0]

well if it has to come off ..the whole of the inlet manifold as well as the exhaust manifold has to come off because they are bolted on with the same bolts on places..plus egr cooler. for the manifolds you need two steel gaskets that are around £15 - £25 each !!!

Original brand new old fashioned manifold with EGR --- not available

something else is available BRAND NEW = probably chinesium - note this replacement that looks completely different ..nether looks like the old fashioned one or the new later one --- which im completely confuses me...no ones tried it ..no ones reported on it !!! --- here

if you are doing that, its a good time to clean the inlet tracts and valves stems ..they will be properly bunged up if over 100.000 miles -- look up walnut blasting

The manual says that there are two sensors ..a cylinder head temperature sensor and and engine coolant temperature sensor - but that statement may be wrong as its kind of hard to know where you are in the manual as it covers a couple of engines and 2760 pages long.

change delboys one first .

all the best.mark

[MXG9]

Just done some research and you’re right, can find absolutely nothing on the old EGR system lol!
So does the EGR unit come away from the manifold? Or is it all one unit?
If it comes away I’ve seen some blanking plates on eBay, if I blank it would that work? A couple people said they’ve just disconnected the top connector of EGR and it’s been fine lol?

The mileage on my 55 plate connect is 170k now, so most likely wants a clean!

Yes I’ll change delboys bottom sensor first and in his video noticed there’s one higher (green sensor) so I’ll check mine see if it’s the same!

Thanks!

[metalworker0]

cant even find the funny looking Chinese replacement now, over a year ago when i found them . - perhaps no one bought them, because they didn't look like the right part ?

NOTE - the manifold and the egr are as one .

but like in said .nothing is unreparable in the righ hands..maybe you can swap parts the top half of the control gizmo is needed over ..and ma\y be swap-able, if you work out a way of doing it


also on ebay now looks like a repair kit for old one ..never seen that before......not really sure here -- and i found them earlier and cant find them now ! why is ebay so difficult to search these days ..seems like you have to put in " " or you get anything ..

also ..if you are into taking things apart that are not meant to be taken apart ..egr for early transit mk6 - will be a wild guess if it works ...and no manifold to undo ..you are just changing the top

https://www.ebay.co.uk/itm/185046436209?

all speculation ..as it actually may be just vac pipe issues

all the best.mark

[metalworker0]

Just done some research and you’re right, can find absolutely nothing on the old EGR system lol!
So does the EGR unit come away from the manifold? Or is it all one unit?
If it comes away I’ve seen some blanking plates on eBay, if I blank it would that work? A couple people said they’ve just disconnected the top connector of EGR and it’s been fine lol?

The mileage on my 55 plate connect is 170k now, so most likely wants a clean!

Yes I’ll change delboys bottom sensor first and in his video noticed there’s one higher (green sensor) so I’ll check mine see if it’s the same!

Thanks!

higher green one is oil pressure