2016 Relay 2.2 Puma SID208 Euro5 Paranoia Not running well

[BingoBill]

Hello - I have some issue with my van - its just a nagging feeling and I dont want to ignore it and
create a bigger issue by ignoring it...
Apologies if this is a bit of a dump...

Rough Running : Citroen Relay 2016 Puma 2.2 SID208
software ref : 9691854780
software version : 00 00
VIN: VF7**************[VIN obfuscated, can be read by forum staff]
Euro 5 SWB 110BHP 35K

No Engine Management light has ever come on.
Recent MOT passed OK.(after EGR valve change )

Start may need touch on accelerator - fails sometimes - seems worse on colder days.
Idle is regular around 900 rpm ish and engine static revs freely and clutch down 2500 rpm
limiter working ok.
Cold start is 'clanky' then 'dieselly' (is there such a word ?- its not like 2.0Hdi Berlingo PSA diesel)
and needs nursing until up to running temperature - ie. dash indicator climbs then it becomes more refined.
However I can still detect 'pinking' type noise on load and it sounds rough to me.
Cruises in 5th/6th on motorway OK but there seems to be something going on about 3500 rpm
when the note of the engine changes.

Changed new EGR valve to see if it made any difference( QH brand - matched OK) - it didnt.
Cleaned the MAP sensor.
Checked and cleaned the air temp sensor below the inlet manifold - there was a lump of black
carbon sitting on it.

Using Diagbox 7.62 + Lexia Full Chip + S1279 interface. ( is 7.62 the best to use for this issue?)
It fails all the actuators tests for SID208 as 'component faulty
SID208 Mixer Test ('Mixer' is referering to the throttle body I think?)
SID208 EGR Test
SID208 Turbo Pressure Sensor Test
SID208 Test of the variable geometry turbocharger

I also get an oxygen sensor not working complaint(somewhere in Digabox test) but no code and no EM light

All by myself I have now created this new fault in ECU memory : ( No EM light on )
P0488 78 First EGR valve programming value.

I previously saw(and see now) this fault on occasion : ( No EM light on )
P069 21 Lack of coherence between the turbocharging pressure and the athmospheric pressure.

Despite ALL the above it runs Okish - but it doesn't feel right to me.

Sooo ...
I am trying to find a place to start and how to systematically check as everything is 'kind of' working

(1) Should it pass these Diagbox tests - I assume it should but I cant understand how it can fail
these but have no EM light and start & run at least as well as it does ( even if rough ). Am I making some
fundamental error here in expecting it to pass or my Diagbox/ECU version etc etc.

(2) If so which is the 'simplest' of these tests to get working ? Can I find any description anywhere
of what these actuator tests actually do on SID208 - can I get this info on the pay site ?

(3) Can anybody please tell me what the P0488 78 is all about - I can see 'associated variables'
but have no idea what the expected values should be - is this documented anywhere?
I have tried teaching the EGR in the SID208 part replacement menu. I doesnt ask me to run
the engine just turn the ignition off for so many seconds - is this all I have to do?
Have I got a failure elsewhere(eg pressure sensor) which is stopping the ECU getting the expected
response when controlling and teaching the EGR valve ?

(4) Can anybody tell me where the SID208 ECU is reading the turbo and atmospheric pressures
from ? (MAP and ?) Is it expecting its no boost pressure to be the same(or ambient + fixed offset) as the ambient
so its complaining its not getting what it expects ?

(5) Why o why does my oil fill status sometimes appear on the dash and sometimes not?
Have I got another dodgy sensor ?

Randoms:
Amateur - but understand a bit about ECU/CAN/Sensor/Actuator, can use a meter, scope and wrestle with Diagbox.
Ex council vehicle.
Fitted with working 12/240 inverter electrics/board.
Central lock does not work on remote ( unlocking works ) ..maybe switch is duff on remote pcb but I do have
a transponder fault in the BCM ECU.
Leak sometimes causes water to flood out of courtesy light when van moves after standing.
Good cosmetically - no damage - but there was a slight wack to NS front in its previous life which
bent the bumper bar - repaired on purchase - no damage to box/pipe/flowsensor/loom although turbo intake
pipe which dissappears arround the back to the turbo feels a bit rickety.
No ambient temp sensor is fitted in the mirror on this EURO5 variant as far as I can tell by googling and I have no
display at all on the dash.

Any pointers gratefully received - Thanks.

[GiveMeABreak]

You're missing something off the P069* code - it's too short and makes a difference. Options could be P0691 11 or P0692 12.... let me know.

Fault Code:	P0488 78
Description of Fault:	First programming of the EGR valve : Incorrect alignment or adjustment of the EGR valve. Description of the diagnostics: The time of appearance of the fault code is immediate. Conditions of activation of the diagnostics: The following conditions have to be met: - Engine ECU in becoming dormant phase - Ignition on
Conditions for Fault to clear:	3 engine ECU sleep phases
Downgrade Modes whilst Fault is active:	Deactivation of the injection compensation strategies
Symptoms:	Banging/knocking/creaking Crackling / Sputtering / Knocking
Suspect Areas:	Electrical harness Connectors Exhaust gas recycling valve

So as far as the Engine ECU 'sleep Phase' is concerned, I would of expected those to have been met by now, but it won't hurt to do a BSI Reset / Battery Disconnect / Reconnect Procedure reset to ensure it goes to sleep properly.

[BingoBill]

Thanks for the info on P0488 78 - I'll go and try the BSI reset now.

The P069 full code is P069 21

I also get a high pitched electrical whine on the O/S (ish) of the engine bay after I turn off the ignition - its not coming from the ECU module(N/S) but I haven't tracked it down yet - is that 'normal'?

[GiveMeABreak]

Ok, so that code isn't coming up officially, so can't help with that one.

The noise may be from the EGR valve cleaning cycle when switching off engine - used to help prevent it sticking.

[HiNtZ]

Hello - I have some issue with my van - its just a nagging feeling and I dont want to ignore it and
create a bigger issue by ignoring it...
Apologies if this is a bit of a dump...

Rough Running : Citroen Relay 2016 Puma 2.2 SID208
software ref : 9691854780
software version : 00 00
VIN: VF7**************[VIN obfuscated, can be read by forum staff]**************[VIN obfuscated, can be read by forum staff]
Euro 5 SWB 110BHP 35K

Did you get to the bottom of this? I have same van as yours. Euro 5 2016 relay 2.2 (Transit engine)

I just fitted recon engine, brand new injectors (genuine not reman.recon), new throttle body, suction control valve and the van doesnt run right at all.

Injectors are really clicky, lacks power, diesel knock/clatter when under load. Let off the throttle in gear and it sounds sweet on the down rev. But as soon as injection resumes (say on idle or acceleration) it will clatter. There is some very faint smoke, greyish in colour now and then but overall nothing crazy. I've seen vans that run sweet and smoke more.

When starting the van it kind of "cracks" into motion. Like a sharp raspy sound, but always starts first time and idles ok, albeit noisy injectors. The actual running of the engine there's no vibrations, knocking, grinding... nothing. It's definitely something going on in the injection system and I don't think it's mechanical. I'm leaning now more to electrical, as in the ECU. Something is wrong with the injection timing (not mechanically but electronically, the pre injection is absent of delayed I suppose).

Fuel pressure seems fine too, actual/demanded is matching perfectly so pressure is there.

Like you I also find in my Autel in live data to see the programming/learn status of certain items (EGR, turbo, throttle body etc) everything checks out except the O2 sensor saying "not OK". But there isn't one fitted?

I'm actually a mechanic of 20+ years, and this has me stumped.

Let me know if you made any progress. I think we can certainly share some info that might help each other.

Cheers