2.0hdi 90hp Berlingo 2003 non dpf limp mode

[Roadrally]

Hi all
Hope someone might be able to help.

Got a 2003 2.0hdi 90hp Berlingo with the following faults.

pre post heating relay circuit coherence
Permanent fault inlet air temperature signal short circuit to + or open circuit

Had new maf and heater relay (and new glow plugs before I got it)
Pre post heater relay unit (on side of battery tray) had to be rewired.

Had to repair some of the loom wires from ecu that had started to corrode

Faults we're read both on Lexia and pp2000

Anyone else had similar?

Cheers in advance

[Peter.N.]

What's it doing - or not doing?

Peter

[Roadrally]

Dropping into limp mode and staying there

[Peter.N.]

Firstly have you changed the fuel filter? If so another cause of this is the filter in the pressure regulator on the HP pump becoming blocked, this is assuming it has a Bosch fuel system.

Peter

[Roadrally]

Live data is a showing excessive air flow, (450ish) should be 240, egr electrovalve shows 10% and should be between 55 and 80, also now putting out a little white/ blue/ black smoke when revved.
Yes it's had a filter, also drained fuel and replaced with v-power, maf,electrovalve etc
Egr has been off, that's ok and works when you suck the pipe.
Turbo vanes are good, no movement.
Fuel pressure within tolerance so doubt it's a filter in hp pump (is that the 1 in the tank?)

It's the Siemens 801 ecu"

Couldn't get the air pipes out from behind engine so couldn't clean them out.

Will check if timing is correcd
In limp mode all the time now unless left over night

[Northern_Mike]

The Siemens ECU cars don't have an in-tank pump.

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[Roadrally]

That's a bonus, heard of a few in tank pump failures. I presumed that all hdi's had them.

[wheeler]

Live data is a showing excessive air flow, (450ish) should be 240

Has the EGR valve been blanked off ? That would explain the high airflow reading at idle.

[Northern_Mike]

If the EGR is blanked on a Siemens car, it throws a fit aftee a short time and drops into limp mode after not long, and refuses to come out of it.

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[Roadrally]

Egr not blanked, when I took the heat exchanger off the aluminium inlet was almost blocked with oily deposits from resurc.
Egr valve opens and closes sucking on pipe.
Can feel suction from vacuum pump but not sure if it's enough, the electrovalve reading at tick over is only 10% and should be between 55 and 80.
Will put oil flush through just incase there is a build up of gunk in rocker and lifters.

[Roadrally]

Ok, timing perfect, test on foot brake suggests vacuum is good.

Had a chat with cit pug dealer and suggested injection control module (brown 15 pin) which computer says it has but I cannot find at all, had all wiring out so it's not hiding anywhere.

Turbo wastegate is next port of call!

[Roadrally]

Seems to be something temperature related, as it will run ok for a little while, eml light comes on but if you switch the ignition off then it goes out only until the temperature gets up to about 50.
All parameters look good now!
I put a new temp sensor in as soon as I got the van unless it's a faulty one.
No faults logged but light is on permanently when warm?!

Anyone had anything similar?

[wheeler]

Had a chat with cit pug dealer and suggested injection control module (brown 15 pin) which computer says it has but I cannot find at all

I assume they mean the double injection relay ? If so a mk 2 berlingo doesent have one, its integrated into the under bonnet fusebox.

[Roadrally]

Had a chat with cit pug dealer and suggested injection control module (brown 15 pin) which computer says it has but I cannot find at all

I assume they mean the double injection relay ? If so a mk 2 berlingo doesent have one, its integrated into the under bonnet fusebox.

I decided that it was part of the fusebox because I had all the wiring out around the front and couldn't find it.
Don't believe everything the computer says!

[Kone]

Any idea what the solution was finally?
same problem here