So the story this far is I thought I had a stuck Wastegate on the turbo so sourced a new unit and fitted, all went well but found out that the old turbo unit is in good condition and it was the 90⁰ elbow pipe on the cold side of the intercooler leading to the egr valve had a split in it so I have now replaced it with a new pipe, on reassembly I made sure all jubilee clips were good and tight and that the boost sensor plug was in good condition and seated well.

The egr valve is brand new being put on within the last couple of months and it has a brand new injector on #1 cylinder as it failed the leak back test whilst the other 3 leaked back very little.

So the egr valve has a blanking plate in within any holes in it but it had it in when I brought the car so have just put it back in and I'm unsure if it's been deleted from the ECU but when everything was put back together and I tested the car the first time I put my foot down and did abit of hard acceleration the glow plug light came on solid and the car went in to limp mode, bringing up the egr valve code its completely fine if I dont do any hard acceleration.

I don't know what else to try so any help or advice would be greatly appreciated

Rich

 

That is an illegal modification. Be sure to tell your insurer if you don't undo it.

 

Well that wasn't very helpful, I am asking for advice on what the problem could be

 

When it goes in to limp mode do you get flashing glow plug lamp and also do you get engine management light ?
At what fault codes do you get when it goes in to limp mode ?

Paul.

 

Hi paul it is an 04 2.0d sport and I just get a permanently illuminated glow plug light and eml on the dash with the code p0405, the egr valve is the vacuum operated system but all the pipework is in good order with no splits in it

 

Does the vacuum operated egr have a height sensor on it, this will be 3 wires on the top of the valve ?
Reason I ask is that no height sensor is euro 3, and euro 4 for height sensor.

Euro 3 can be blanked without eml, whilst blanked euro 4 will cause eml light.

What I find puzzling is the permanent glow plug light ?

Paul.

 

There is no wiring to the egr valve at all, the permanent glow plug light disappears once I cycle the ignition but it comes back on whenever I do any hard acceleration around 2700rpm or above.

as already stated the car has a new turbo unit fitted within the last 2 weeks, and injector on #1 cylinder is brand new, the other 3 leak back negligible amounts each so they seem good, I have just changed the 90⁰ hose on the cold side of the intercooler and all hoses and jubilee clips are on properly. The vacuum pipework from Wastegate to diaphragm on egr valve is also in good condition, all I'm wondering now is the blanking plate in the egr valve is throwing up a problem or it's a dud egr valve?

 

That means that your engine is euro 3 spec.
As there is no feedback from egr height, the ecu opens the egr by controlling a solenoid valve from a vacuum source, ie the vac pump on the side of the engine.
The only thing the ecu could see as a egr fault is if the egr solenoid or wiring to it is faulty, so check the solenoid supply and wiring back to the ecu.
The ecu switches one end of the solenoid to ground to energise it, so the other side needs a supply.

IIRC the vac solenoid should be by the starter motor on a plate.

Paul.

 

Thanks Paul, I will check it out tomorrow weather permitting to see it there is anything that needs attention with the vac pump and update you further

 

You NEED to be insured! With such a mod you are not.

It's a painful truth but insurance is strict liability.