Mk6 lack of power p0235 and p0110 fault codes

[Pegman1184]

Hey guys
Firstly excuse me if I am in the wrong part of the forum .
I have recently bought a 2002 fwd t260 100 swb transit.
The van has done a few miles but is in excellent condition. I've had it for about a month but am unfortunately still awaiting my first journey in it.

The van has serious lack of power and you would almost think the van was no turbo'd. I had the codes read by a garage and the codes p0235( turbo boost sensor malfunction ) and p0110 (air intake temperature sensor malfunction). This was the information I got from the garage on the codes.

I am just looking on information on what sensors I am actually looking for and also where about these are located. I have phoned ford dealers and a local ford parts stockist and have had varied answers regarding sensors. I've been told the air intake temp sensor is a MAP sensor which is located on the inter cooler hose and is easily replaced. I was also told there is a sensor on the inter cooler itself. Can anyone confirm?

The boost sensor is causing some confusion with guy at ford saying that he hasn't heard of it. The other local parts dealer said it comes as part of a hose which connects to the egr valve.

Any info on anything in this thred would be greatly appreciated. I'm just needing her back on the road asap

[RyanJJones]

lol!

Guess what I wrote today http://www.doyourdream.co.uk/2013/10/fo ... 235-fixed/

By getting both errors, I would guess your MAP sensor is failed or not plugged in or indeed a wiring fault. See my link above should answer your questions? Mine is a different engine, but most pointers should be the same? The MAP sensor does BARO (air) IAT (inlet air temp) and MAP (boost pressure) - so as you have 2 errors relating to the same device - thats quite a clear messge...

Your sensor is in the off-site bottom part of the intercooler.

[Pegman1184]

Thanks mate
That is really handy . Thanks for your reply. Do you reckon I should just try and change out the map sensor first and see how I get on?

[RyanJJones]

Thanks mate
That is really handy . Thanks for your reply. Do you reckon I should just try and change out the map sensor first and see how I get on?

If you have money to burn!

Personally I'd:-
- check its plugged in, and reseat cable
- check it has earth & +5v on the appropriate pins (see my doc for pin layout)
- buy f-super and see if the ECU can read it and give accurate values (I expect not)
- IF it has +5v AND it has earth, and cables look okay, AND f-super reports incorrect values, I'd check wiring back to near ECU and do a continuity test

Only then, if that test said continuity would I consider changing MAP sensor.

(I'd also rule out crap in the intercooler, and ensure there is airflow through it).

Thats probably the cheapest way to go, and simplest really....

[Pegman1184]

Got the van back today and the mechanic has cleared the codes and van is running slightly better although I'd say its definitely down on power? Am I better to try blank egr and clean out Inlet to see how I get on?

Also heard that pedal sender can cause lack of power??

Any ideas gents?

[stevo]

Check for any split pipes, could be a pipe coming from the turbo is split.

[Pegman1184]

Thanks mate. Is the actual egr valve behind the block near to the turbo? What's best way to check if pipes are damaged, just a visual inspection or are would they produce bubbles etc if covered in soapy suds due to gas escaping?

[RyanJJones]

Thanks mate. Is the actual egr valve behind the block near to the turbo? What's best way to check if pipes are damaged, just a visual inspection or are would they produce bubbles etc if covered in soapy suds due to gas escaping?

Follow the vacuum tube to find the EGR - again see my sig - full pictures where it is Its on the Near-side part of the engine not quite as far back as the turbo.

My pipes were all fine, I took them off and checked for splits as I had heard that some splits only show on boost and you can't replicate that stationary.

I doub't your hoses are split though - just p0235 maybe, but p0110 as well which is from the same sensor.... I don't believe in coincidences and a split hose would not give a p0110.

I'd definately err towards sensor/wiring....

[Pegman1184]

I'm gonna change out the fuel filter today and give it some diesel additive see how I get on. Also I'll clean out inter cooler and inlet and check wiring on map sensor on inter cooler hose and report back. Thanks again for your help

[Pegman1184]

Gents
Changed out fuel filter today and filled filter with wanna fuel system cleaner. I also took apart all of the sensors withing the engine bay and inter cooler, cleaned with electrical cleaner and re attached. Van is back boosting as it should so thank you for all your help. One other question I have is that I noticed a lot of black oily gunk in some of the air pipes and inlet manifold. Is this worth taking off and cleaning up ? I presume the answer is yes but if it's not harming anything then it saves me a job

[blue estate]

Take the manifold and pipe off clean them and blank the Egr as the gunk is soot mixed with oil also use new seals
You'll see why I said to clean it when you see how blocked it is
This is my inlet manifold and my van is a 2010



My egr is now blanked and the pipes are as clean as when I cleaned them in may

[thog]

Message to Ryan or anyone that can help!?
I am desperate here. I was reading a post in the forum and saw you are the author of that excellent do your dream article which I have read a few times so thought you might be able to help me.

On my 2006 Mk6 2.4Di 115 RWD, someone cut the wires and stole the connection plug that goes onto my MAP sensor, I have managed to get another plug to connect to the sensor but it is from a mondeo so the wire colours are different.

My basic problem is: I need to know in what order the 4 wires connect to the sensor pins, my wire colours from wiring loom on van are: orange/grey, white/thin green line, white/thick green line and brown/green.

I tried to look on your photo on that article to see if you had the same colours but couldn't see well enough, if you do have the same colours and if you could tell me in what order to connect them then I would be enormously grateful, I have posted pleas in the forums begging for help but they've all been ignored.

In desperation I started connecting the wires in different combinations until the glow plug stopped flashing, so I thought I had got the right combination, but the van has no power- the same as when the sensor is disconnected. I paid a guy to test it for me yesterday and he said it is showing IAT fault and showing -41'C temperature. I am wary of further experimentation in case I short circuit the ECU. Indeed the mechanic said I may actually have the wiring correct but may have fried the sensor with my experimenting.

Looking at the open sensor pins, with the sensor sitting on top of the air tubing, so counting left to right like that I currently get the following voltages:

1. 1.8v connected to sensor/ 5v disconnected
2. various voltages within 15 minutes checking connected: 1.8, then 4.5 then 3.8v/ 0v disconnected
3. 0v disconnected & connected
4. 1.8v connected/ 5v disconnected

I would be VERY grateful for ANY help you can give, thank you, Ian.

[thog]

P.S.

None of these voltages changed when van was started and revved...