New toy with issues

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moizeau
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New toy with issues

Post by moizeau »

As some know and some may not, I'm the new owner of Rich's Dispatch. It's now on the drive and underwent it's first Diag session under my ownership.

The results ladies and gentlemen are:-

1st read:
2 BSI faults
-A4CA - Rear LH fog short to +ve. Nice one, so it has 2 fogs, yippee.
-F5FF - Unexpected reinitialisation fault from BSI

10 Injection / Ignition faults
-P0490 - EGR Position Copy (from now on known as EPC) - Value opening too small, intermittant.
-P1459 - EPC - Valve stuck open.
-P0405 - EPC - System volts too low.
-P1351 - Preheat relay supplied but not plugs. (To be ignored)
-P0401 - Air circuit - Air flow higher than recommended.
-P0409 - EPC - Valve stuck during programming.
-P0489 - EPC - Valve opening too large.
-P1162 - EPC - Valve stuck when driving.
-P0704 - Clutch signal switch - No signal or talking cobblers.
-P0344 - Camshaft signal - Signal temporarily incorrect or missing.

Definitely a trend here. All cleared then re-read without starting the engine.

2nd read:
2 BSI faults, as above.

2 Inj / Ig faults.
-P0405 (see above)
-P1728 - Can communication,Torque info invalid.

BSI reset done, started engine, didn't drive, re-read faults.

2 BSI faults, as above.

6 Inj / Ig faults.
-P0405 - EPC
-P1728 - Torque info
-P0409 - EPC
-P0490 - EPC
-P0401 - Air circuit
-P1459 - EPC

Next step, actuator tests.
Electric EGR valve, diddly squat.
Butterfly valve, one or two clicks.
Turbo solenoid, apparently it should vibrate, I've no idea where I'm supposed to be feeling, so ignored for the moment.

So there we have it, off to read the BOL's about EGR placement, access, removing and look on here for tips on checking and cleaning.
If anyone would like to give some advice, feel very free to, it will be much appreciated.
Cheers

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GiveMeABreak
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Re: New toy with issues

Post by GiveMeABreak »

I'm sure I covered some of these in the old threads Pete, but P0405 is the one I would check first - as that is the one concerning the voltage: I suspect if this is not getting the supply, then it may cause the other issues.
P0405: Electric EGR valve repeat signal fault: Copy voltage too low.

Suspects:
  • Engine ECU 5V shared supply
  • Electrical harness
  • Electric exhaust gas recycling valve

moizeau
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Re: New toy with issues

Post by moizeau »

Cheers Marc, can this be checked at the plug for the EGR, to see if 5v is arriving?

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GiveMeABreak
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Re: New toy with issues

Post by GiveMeABreak »

They list: Adaptor harnesses, multimeter, Controlled terminal box (in manual mode) or manual terminal box.....as the appropriate tools.

This is a shared 5V supply, so maybe they use the adapter harness to isolate the specific connection...?

moizeau
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Re: New toy with issues

Post by moizeau »

Ok, thanks, I'll a dig tomorrow

RPWC
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Re: New toy with issues

Post by RPWC »

Good luck with the fault finding Pete. At least you have the tools to find the faults. All that would be beyond my mechanical capabilities. It needs someone like yourself to do the digging and fettling😉

moizeau
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Re: New toy with issues

Post by moizeau »

Thanks Rich, time will tell.

moizeau
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Re: New toy with issues

Post by moizeau »

Update, it's got 2 rear fogs. (Under no circumstance am I apportioning blame on Rich with anything written in the follow ups) The bulb was missing (probably due to a crack in the lens that would let white light out) with the RHS still working it would be good for the MOT.
Got to the EGR, that's fun! It's buggered, mechanically and electrically. I have got 5v to the orange wire in the plug. Photos to follow

moizeau
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Re: New toy with issues

Post by moizeau »

Took the EGR out and did an actuator test, still nothing.
I couldn't find a definitive pinout for the plug so I probed all the pins with the +ve terminal and the -ve on the engine (ig on). The orange wire, left hand most with the tang to the bottom gave me 5v.
I then took the 2 halves apart (rv6 socket) and plugged in the electrical side and repeated the actuator test. This should now turn one way then the other (like a servo motor),...nothing. Not surprising really
IMG_3149.JPG
It as black as it looks.

Then I looked at the mechanical side
IMG_3151.JPG
The 'clock hands' move on a small worm and should be smooth. It took some force to move it. It was stuck shut when I took it off. Either end of the worm is damaged so the clock hands are locked in position until brute force or vibration allows movement.
The other thing is that the sleeve with the worm and clock hands is loose, that can't be right.

So it's buggered, seen aftermarket versions for 50 euros and a Valeo for 120.
I also think that someone has been here before unless the reverse torx screws get damaged on their initial tightening and Cit fit the more expensive EGR clips with a 5mm allen screw as standard?

All participation welcome

moizeau
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Re: New toy with issues

Post by moizeau »

Called into the tat yard to see if they'd got any LHD headlights, which they hadn't (well not for my van anyway) and took the opportunity to peruse the 1.6HDI lumps. Saw one that had been partially dismantled (Fuel Filter gone) exposing an EGR valve ready to come off. So I obliged. I realise it's a risk with a second hand part but I can test it without putting the vehicle back together and they give you a 3 month test period, receipt and money back if it's knackered. So not really a risk of 30 euros.
Plugged it in, BSI reset, cleared faults from the previous EGR, did an actuator test.......and got some clicks. Checked faults again. Only one remains,
-F5FF - Unexpected reinitialisation fault from BSI.
So far looks like it's heading in the right direction.
Off to bolt everything back together in order to start the engine, check for faults and do a perimeter check.
Wish me luck!

admiral51
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Re: New toy with issues

Post by admiral51 »

Seems like you have it all under control

moizeau
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Re: New toy with issues

Post by moizeau »

Spoke too soon thinking this was going to be finished today.
A note to anyone that hasn't taken an EGR valve off one of these engines - slightly unscrew the heat exchanger mounting nut to give it some free movement prior to removing the EGR. The reason being, if you don't it damages the mating face on the heat exchanger thus not allowing you to make an (exhaust) air tight joint possibly leading to an engine fire. Fortunately, due too a previous experience with this clip I noticed the fit wasn't good and the mating face damaged. After repeated attempts to re-shape it, in vain, I've had to take the heat exchanger off so it can be sorted on a bench. Drain the water, remove the water hoses, one of the spring clips broke and took 15 mins to get the hose off. All at an obscure angle with your knees trying to bend the wrong way....nice. I should have done a test drive an hour or so ago.
It's beer o'clock now, so back to it tomorrow.

RPWC
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Re: New toy with issues

Post by RPWC »

Good to hear progress being made Pete. It wasn't me thst had a go at the egr, as I said on the phone, too much of a p i ta job for me. Beer o clock for me too
20200229_200426.jpg
someone rotate the photo please.😂
Last edited by myglaren on 29 Feb 2020, 23:57, edited 1 time in total.
Reason: Stood that man on his feet.

moizeau
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Re: New toy with issues

Post by moizeau »

Cheers Rich, I'm on the wine now, helps me to relax....

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Paul-R
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Re: New toy with issues

Post by Paul-R »

RPWC wrote:
29 Feb 2020, 21:20
someone rotate the photo please.
Nah. The camera is correct, it's the room that needs rotating.