Berlingo 1.6 hdi. 2009 model

[Mac194]

Morning all
I’ve got an issue with a van that has me scratching my head a little. So before Xmas it kept saying internal fuel leak and low fuel pressure. Can’t remember exactly what it was showing pressure but I changed the HP pump and the fuel pressure sensor. Went to start the vehicle and it just wouldn’t run. Kept trying it and checking connections and it burst into life. No eml light on and it struggled to Rev. But seemed to get better as it warmed up.
Left it a few hours and again. Struggled to get started but this time smoked real bad white/grey to black smoke. It sounded like it was being choked up so I had look at egr and that’s when I started getting codes
P0405
P2143
P2145
P0215
It appears I have 5v ref on a pink wire. And that is all I have. Really unsure on how to proceeds from here.
I have fuel pressure of around 350 bar at idle. I stripped timing covers back off and double checked timing which is spot on too.

Many thanks for any input anyone may have.

[GiveMeABreak]

Pop your VIN up so I can determine the exact engine to relate the fault codes to (please post your VIN in full without spaces - it will be automatically masked from public view after submitting your post & will only be visible to staff).

[Mac194]

Thanks Marc. Van is at work so I will do this first thing in the morning. Much appreciated mate.

[Mac194]

VF7**************[VIN obfuscated, can be read by forum staff]

[GiveMeABreak]

Ok, so here are the fault codes as they relate to your DV6BUTED4 engine (no DPF fitted).

Fault Code:	P0405
Description of Fault:	Electric EGR valve repeat signal fault : Copy voltage too low.
Conditions for returning of the fault:	When the valve is controlled: The fault codes are returned immediately in the engine management ECU The diagnostic warning light only comes on and switches off after 3 engine starting cycles (**)
Downgrade Modes whilst Fault is active:	The engine ECU cuts the regulating of the EGR (*) The electric EGR valve auto-programming operations are no longer carried out.
Symptoms:	Switching on of the diagnostic warning light Noise: Cold
Suspect Areas:	Engine ECU 5V shared supply Electrical harness Electric exhaust gas recycling valve

(*) Consequence for the parameter measurements:

• Electric EGR valve control OCR = 0 %
• Position repeat = 0 %

(**) 1 Starting cycles:

• Engine start
• Engine cut-off
• Wait for the instrument panel to switch off

Tools: Adaptor harnesses, multimeter, Controlled terminal box (in manual mode) or manual terminal box

Fault Code:	P2143
Description of Fault:	Exhaust gas recycling electric valve control: Open circuit. Open circuit for 200 ms.
Conditions for Fault to clear:	Ignition on.
Downgrade Modes whilst Fault is active:	Deactivation of flowmeter plausibility faults The ECU stops the regulation of the EGR valve The ECU stops the regulation of the EGR butterfly The ECU cuts the regulation of the by-pass meter Deactivation of the initialisations of the EGR valve
Symptoms:	Lack of power Engine hesitating, cutting out
Suspect Areas:	Exhaust gas recycling valve Electrical harness Connector

Fault Code:	P2145
Description of Fault:	Exhaust gas recycling electric valve control: Short circuit to positive. Short circuit to positive for 200 ms.
Conditions for Fault to clear:	Ignition on.
Downgrade Modes whilst Fault is active:	Deactivation of flowmeter plausibility faults The ECU stops the regulation of the EGR valve The ECU stops the regulation of the EGR butterfly The ECU cuts the regulation of the by-pass meter Deactivation of the initialisations of the EGR valve
Symptoms:	Lack of power
Suspect Areas:	Electric exhaust gas recycling valve Connector Electrical harness

Fault Code:	P0215
Description of Fault:	Supply relay control: Short circuit to earth or short circuit to positive or open circuit. Main relay remains stuck during the phase in which the engine management ECU becomes dormant.
Conditions for Fault to clear:	Ignition on.
Downgrade Modes whilst Fault is active:	-
Symptoms:	Starting problem.
Suspect Areas:	Engine fuse box Electrical harness Connector

[Mac194]

Thanks Marc. I appreciate that work you’ve put in there. Gives me some more to work with.
I established today I had no 12v supply directly out of the Ecu. It would randomly go live for a few seconds then went back to a hood earth. I also noted that the red wire would also go live too. My 5v ref was present. I’ve blanked the egr off and it’s running real well. Obviously this is giving an anti pollution fault and eml light on permanent.
I’ve concluded that it’s an Ecu error. Can’t imagine my boss wanting to pay out on a new Ecu for this at its age and mileage. Which is a shame, I really wanted to see how much this van would do.
I guess my other option is an egr delete….while I’m there I may as well get a bit more bhp out of it.

Any ideas where the supply relay is ?

[GiveMeABreak]

Hi Mac, please note we don't support any emissions crippling or tampering on the Forum as it's illegal (please refer to out AUP (7)) here: viewtopic.php?t=56502, so expect faults if you have removed or disabled them. Annoying as the system can be when it gets dirty, the EGR is part of the emissions system as it reduces NOx.

[Mac194]

Sorry Marc. Forgive me.
Now that I know it runs perfect it’s given me a new spark. I’d like to just repair it. How difficult would it be to change the Ecu? Never done anything like that on one of these. I assume it would need programmed to the vehicle ?
Watching that voltage drop in and out today really tells me that it’s an Ecu issue. And eve is probably ok.
Sorry again. I’ll familiarise my self for the future.

[GiveMeABreak]

No worries,

The ECU, BSI and Immobiliser chips in the key or fobs are paired, so can't just be replaced. If you are contemplating replacing the engine ECU then it would need to be 'virginised' first by a specialist before it could be reconfigured. There may be specialists than can clone the configuration for you from the old to the replacement, but I've never needed to do this. Normally the ECU would need to go to a dealer for configuration and pairing unless you know what you are doing and have all the kit to do this.

[Mac194]

Cheers for the info Marc. It’s parked up till I can figure a solution.