2500-3000rpm EML?

[Frosty149]

Afternoon, been having a bit of a dance around a intermittent misfire as follows:

1. EML and limp mode kicks in following a lumpy/miss at 2500-3000rpm.
   
2. Intermittent but getting worse/more frequent - seems to be more prevalent in cold weather (even though the engine is hot).
   
3. Switch off and allow a reset often resolved and it drives as normal, unless it’s cold - then it returns.
   

Changed MAF, no change.
Checked vacuum pipes, all seem good.
Checked vacuum switch and run with and without elec connection, no change.
Squirted a can of egr cleaner through as instructions, no change.
Lexia says ‘Permanent fault, Air circuit, quantity of cold air less than the setting’
Fault code p0402
Getting the EGR valve out for a clean up looks a pig of a job and this temperature thing seems to relate to a the weather related symptoms?
I’m reasonably handy with a spanner, but, don’t want to make a pile of bits looking in the wrong direction!

Am I missing something obvious?
This electrickery has me stumped ? 
Thanks for any thoughts...

[Satellitemark]

You could try disconnecting any wires going to the egr to see what happens .
Here is a video about the removal of the egr I found on YouTube.


https://youtu.be/G0cXkfnVKlY

Mark

Sent from my VFD 710 using Tapatalk

[Frosty149]

Sorry, the vehicle is an ‘05 2.0 hdi Berlingo (RHY) van, @130k miles.
Thanks for your help...

[Frosty149]

No wires to the egr, only the vacuum solenoid thingy, tried with wires connected and disconnected - same limp mode outcome?

[cancunia]

Fault code p0402 is too much EGR so yours may be stuck open.

Some things to try on that front:
1, Do you still get the same fault code with the vacuum tube removed at the EGR end & blocked?
Block the tube to be safe as it also provides vacuum for the brake servo.
2, With a tube connected to the EGR can you hear it click closed when you suck on the tube and let it go quickly? Trying this a few times might help free the EGR if it's stuck.

I'm running my 2.0 with the electrical connection to the Solenoid disconnected. I get the EML on all the time, but no limp mode.

[Frosty149]

No ‘click’ from the egr when you suck on the pipe.
I’ll disconnect and block it for tomorrow mornings commute and report back....
Don’t mind the EML, but limp on a 40 mile, hilly motorway run is driving me mad!
Thanks for the help.

[Frosty149]

Ok tried it this morning with the vacuum hose disconnected and bunged, still got limp mode with the light (when it came on)...
Worth a try, thanks.

[cancunia]

Ok tried it this morning with the vacuum hose disconnected and bunged, still got limp mode with the light (when it came on)...
Worth a try, thanks.

Do you also have the solenoid electrically disconnected by removing the connector plug? Maybe also worth clearing all the fault codes. The solenoid disconnection will throw a fault code & EML but clearing the codes may take away the limp mode.

[Gravity]

I have never known a can of EGR cleaner to actually clean and restore the full operation of the egr valve. Snake oil.

The only way to really clean an egr valve is to remove it and then scrape the muck off and free it up. As you get hot and sweaty trying to clean it you will understand why a squirty can will not do the same job.
If you suspect egr malfunction there is no shortcut.

Do you have a fault code scanner? If so, remove and clean the egr and then clear any stored codes before testing the vehicle.

Gravity

[cancunia]

As above re the EGR, but I'm surprised about limp mode if the solenoid is disconnected & faults cleared after. I've been running mine for a few weeks with the solenoid disconnected, I get the EML & 'Anti Pollution Fault' warning on my MFD but otherwise it's running fine.
I did read elsewhere that different ECU software versions behave differently, some apparently don't give an EML with the solenoid disconnected.
I will tackle my EGR removal & clean when the weather gets a bit warmer, probably not before April or May.