Berlingo surging then rattling

[Crayford]

I have a 2004 1.9 Berlingo that has done 80k. At about 2000-2500 constant speed the car will surge then rattle as it decelerates then drive normally for a little while then repeats. Only seems to happen when driving, nothing when stationary. It has been in main dealer for 2 weeks but still faulty. Starts immediately, had new air and fuel filters and no fault codes show on Citroen computer. Any help would be much appreciated. Thanks.

[chinkostu]

Try Disconnecting the vac line to the EGR (crimp it temporarily)

My 206 did the same, the egr was partially stuck

[Crayford]

Would this be the pipe from the top of the EGR solenoid? Could this cause the rattling noise similar to camshaft wear? Thanks, Mike. Also have high fuel consumption and black smoke

[chinkostu]

Suprisingly yea. Ours runs like a dog with it connected! The pipe runs from the vac line at the bulkhead over to underneath the egr assembly if i remember correctly.

The only other thing would be the pumps running advanced too far.

[Crayford]

Thanks for that tip.........that has stopped the surging and rattling. Still got the black smoke and high fuel consumption but will attack the EGR valve and try cleaning or blanking it off. If it's still problematic will maybe have to get the fuel pump etc tested. Appreciate your help.......Thanks, Mike

[chinkostu]

If you can, whip the egr off and see if it moves smoothly. Could be stuck open!

Air and fuel filter clean?

[Crayford]

Removed and had a good clean-up of the EGR. Butterly open on normal and closed by sucking on vacuum pipe so assume it works ok. Couldn't see how to test the needle valve unless by attaching a tube on and sucking to create another vacuum. Lots of cleaner and scraping then reassembled. Now seems better but still not right........much gentler surging/slowing at about 2000 rpm. Have taken it for long run, mostly at 3500 rpm, to try and clear the crud. Less black smoke but still some there. I wonder whether it needs more running to clear things out or if the EGR will still need replacing. If they are clean, is there much that can go wrong with them? Regards, Mike

[chinkostu]

Removed and had a good clean-up of the EGR. Butterly open on normal and closed by sucking on vacuum pipe so assume it works ok. Couldn't see how to test the needle valve unless by attaching a tube on and sucking to create another vacuum. Lots of cleaner and scraping then reassembled. Now seems better but still not right........much gentler surging/slowing at about 2000 rpm. Have taken it for long run, mostly at 3500 rpm, to try and clear the crud. Less black smoke but still some there. I wonder whether it needs more running to clear things out or if the EGR will still need replacing. If they are clean, is there much that can go wrong with them? Regards, Mike

when was the last time the fuel and air filters were checked? it is worth disabling the egr completely to rule it out if needs be, either with the vac line plugged or a blanking plate.

also, check the wiring on the little pot thats on top of the fuel pump. mine had a dodgy wire that make the car undriveable in the wet as it thought i was at full pelt when pottering

[Crayford]

Fuel and air filters changed and MAF cleaned before dealer attacked it. Blocked vacuum pipe which cured excessive surging and rattling, which I assume was the EGR needle valve clonking about. Still had black smoke but reluctant to undo exhaust bolts to fit a blanking plate as they are bound to shear-off. I don't know if blanking off or plugging the vacuum will stop the smoke, if it is carbon build-up being cleared or if there is a secondary problem causing the excess fuel/smoking scenarion. Just done a fuel consumption test an got 34 mpg. Will check the wiring connections next.

[chinkostu]

Nah doesnt sound like egr with the smoke. Almost like its overfuelling or incomplete combustion. As said, check those wires,

[Crayford]

Have now cleaned connections and re-cleaned EGR. Butterfly and needle valve tested and seemed to work ok and given it another hard drive. It was obviously the needle valve that was maing the ratling noise. I think there is now less smoke and just clearing soot out of the system and doesn't seem to smell of fuel as much. My local garage can't test fuel pressures etc and would just start changing parts so wont bother with them. They also suggested putting a jetwash up the exhaust to help clear it but will hold off on that for a while and see if it clears by normal use. Just want to say thank you for your help and suggestions with this problem. Kind regards, Mike

[chinkostu]

Awesome! I'm never a fan of the semi-electric diesels as its all the great bits of a mechanical with hashjob electrics! Its very very simiilar to our troublesome 206 which is too rotten to be wasting time on! But they're a nice if slightly unrefined drive, the wife gets great mileage out of hers. Shame it sounds like a tank!

If the car around it is good then it's worth looking after the engine as they're still fairly bombproof

[Crayford]

I now have a 2016 berlingo 100hdi with 24000km. Last month the amber engine check light appeared immediately with daily usage, but by leaving the car unused for a day it would next appear after about 5km. Local garage checked and said one of the 2 nox sensors/injectors was faulty but not sure which one so go to Citroen dealer. They checked and said nothing wrong with the car, cancelled the light and said there may be a software update from Citroen so try it and see if it reappears. So 30km later it came back on so back to Citroen. They then said a nox sensor/injector was faulty and changed it but also now say the urea tank is faulty and needs replacing, please leave us a signed blank cheque!!
My question is why didn't, or wouldn't, these faults show on their initial test or would one fault hide the other?

Thanks, Frustrated in Fuerteventura

[wheeler]

What fault codes logged in the system & did they give you a print out? Did they do a software update? As for the nox sensor fault if there is an issue with the urea system it can give odd reading on the nox sensor giving the impression of it being faulty.

[Doo]

I now have a 2016 berlingo 100hdi with 24000km. Last month the amber engine check light appeared immediately with daily usage, but by leaving the car unused for a day it would next appear after about 5km. Local garage checked and said one of the 2 nox sensors/injectors was faulty but not sure which one so go to Citroen dealer. They checked and said nothing wrong with the car, cancelled the light and said there may be a software update from Citroen so try it and see if it reappears. So 30km later it came back on so back to Citroen. They then said a nox sensor/injector was faulty and changed it but also now say the urea tank is faulty and needs replacing, please leave us a signed blank cheque!!
My question is why didn't, or wouldn't, these faults show on their initial test or would one fault hide the other?

Thanks, Frustrated in Fuerteventura

Does the car drive normally other than the light coming on?

Engine waring lamp is usually lit for any number of reasons, but I have found it is normally a fuelling issue (exhaust, inlet, coolant) of some description that the computer has picked up via the sensors. But this is all well and good if said sensors are operating within correct parameters. It's even possible some bad fuel isn't helping matters....

If the Citroen garage didn't find anything, it doesn't mean there isn't a problem. These engines are pretty good. I have a C4 with the 16v DV6 and a Berlingo with the 8v DV6. The Lingo has 153k on it and the C4 has a mere 95k. Apart from injector issues (couldn't get them out to get at a broken glow plug tip... Long story) the engine has been absolutely reliable.

Has the little gauze been removed from the turbo oil feed pipe? It's inside the banjo bolt and I recommend having it done to save the turbo.

If your engine only has 24k, then it's barely run in