Focus MkII 1.6 TDCi 2007 reg

Sometime ago EGR valve caused the car to get into limp mode. Tried the intake cleaner with EGR being removed and manually cleaned (ford service did this), but didn't help much. Following ECU reset, the limp mode would come back a few minutes later.

Being absolutely assured that this was caused by an EGR valve fault, I had the entire EGR valve assembly replaced with a brand new one. The cleaning and the EGR replacement cost more than £500.

Unfortunately, just 1 day after the EGR replacement, limp mode kicked-in again. As per the service station the following codes are active:
- P0490 EGR control permanent
- 042F1 unknown fault code

Any ideas what could be the problem?

 

I hope you haven't paid yet. If the garage diagnosed the fault as the EGR valve and it clearly wasn't, then get them to take it off and put your old unit back on.

These are shitty horrible Peugeot engines, they are a nightmare for faults like this. I'd be checking for wiring faults, or split/leaking vacuum pipes etc.

 

Of course they have been paid for...and there is no turning back. Wiring has been checked (presumably) and no faults have been found. As far as I know there are no vacuum pipes associated with the EGR system.

 

EGR on these is an electrically controlled motor.

The fault seems to be the control circuit rather than the valve itself (Problem with wiring/ECU)

I would be going back to where I'd paid £500, if it's faulted again in one day!

042F1 - no idea what that is.

 

I need to do some troubleshooting myself. Service station gave up, not to mention that every time I take the car for repairs/testing, it has to stay there overnight. I tried to install Ford ETIS but it doesn't work since it's a 32bit software and won't run on 64bit windows
Is there a good source of ford workshop manual out there?

 

ETIS won't really help you, as it just mostly says refer to WDS/IDS for faults.

Sorry, but if you've spent £500 on a mis-diagnosed fault they can't really 'give up'

 

not 100% as i work more on commercials but dont you have to reset the egr's learned values or somthing to do with the egr needs reseting when fitted to the 1.6tdci.

 

Yep, true that Bram, same as the 2.0 DW engines, the garage should have done that, before 'giving-up'

I did a quick Google with the OPs code of P0490 and found this thread

http://www.bba-reman.com/forums/PrintTopic130757.aspx

Turned out to be an ECU fault. The wiring needs checking of course.

 

Useful but at the same time a very scary link! Ford OEM EGR was not in stock so I provided a non-OEM EGR from TPUK. Does that mean now that the non-OEM EGR fried the ECU? That's a nightmare.

 

Seriously would be going back to the place that did the repair.

 

Did you diagnose the fault yourself, got the bits, and got the garage to fit them? Or did you give it to the garage, they diagnosed it and put the new EGR on?

 

you may also want to check the dpf and make sure its not clogged and news a regen service. have it deleted and the egr removed and remapped. problem sorted.

 

The Garage diagnosed the EGR and initially did some cleaning with diesel intake cleaner, which didn't work out. The Garage then suggested that the EGR should be replaced with a new one, but unfortunately the OEM was not in stock by Ford. I then decided to buy a new one from TPUK (which looked exactly like the original one, and the connectors would measure the same resistance before fitting). That was installed by the Garage. It's a mess!

 

If the dealer has misdiagnosed the issue they should sort it for you. If the dealer was Peoples of Liverpool ask to speak to Joe Crawford. If he is still there he is/was the main man for the service departments.

 

Any experience out there with EGR valves sold by TPUK (Transit Parts UK)? I worry that this non-OEM valve may not behave as expected by the ECU.