Hi I have a problem with 2004. ford c-max 1.6 80kw diesel engine, with manual transmission, 200000 km odo.
It came in, with check engine light on. Diagnosis shows P1412 and P0404 fault codes.
When i removed EGR valve, noticed it's suspiciously clean, no carbon buildup. And then noticed DIY sheet metal blind between the seal.Someone has been already messing with that.
I replaced EGR valve with one, from junkyard.
Before putting it on, tested it. Connected the wires, and when ignition turned on, EGR valve inner valve part moved. This means it should work.
After installation, I run diagnostic, now check engine light turns off, when engine starts. But fault codes still present.
Runned EGR valve calibration program, still no result.
Now some reason engine does not go over 3000 rpm. I double checked, wire connections and hoses what i might touched, but everything looks ok.
Even tested the vacuum system. I know this type engine had sometimes problems with vacuum systems, and that causes problems with turbo waste gate,and makes the turbo weak. vacuum pump side pulls round 0,8u and turbo side vacum is round 0,1u
Other things i tried; new fuel filter, new air filter, run with removed DPF filter, swap tested air sensor, even tried run with that DIY blind, what was on EGR before, still don't go over 30000 rpm.
Any ideas?
Mystery continues, there is now brand new EGRvalve. Checking the live data with diagnostics, I discovered that one of the "EGRvalve duty cycle" is 0. then I deleted the fault codes. and car start worked fine. live dada showed EGRvalve working, RPM went to max and works fine. Problem is it lasts until you turn the engine off. if you start the engine again, everything is back to the old way. max RPM is 30000, and fault codes are back. 5 wires go to the ECU. I load tested the wires and they were ok.
Which fault codes are showing? The P1412 and P0404 EGR ones?
ECM. Has only two fault codes.
P0404 - Exhaust gas recirculation control circuit range/performance - permanent
P1412 - Exhaust gas recirculation valve frozen - permanent
maybe the exhaust end of the EGR tube is plugged up with carbon from being block so long?
EGR channels are not blocked, checked with camera. Stuck open EGR valve can make run engine run weak.
With Blocked EGR, engine should kind of work. My suspicion is, there something else, what causing that low rpm.