2.2 DTi Spanner & Limp mode

[pfj]

Had a problem for a few days and although I found much very usefull info in these forums - I need some help !
Had the car, a Nov02 2.2 DTi for over 5 years. It's now done 110K with very few problems except for the dreaded spanner coming on - usually in 4th or 5th if I changed up too early. Ignition off / on and it always reset - that is until now.!
On those past occasions, it went into a form of limp mode but was still easily capable of 80mph - just took longer to get there and hills could be slow but as I said, ignition off / on and it cleared anyway.

The new problem kicks in as soon as the engine gets to a normal temperature. It starts from cold first time even in the very cold weather and runs well for about 4 - 5 miles - then the spanner and into limp mode.
I should say, the engine management light never lights (except with ignition on at start-up) so I haven't tried to read the codes - any point ?
Limp mode now is like running on 3 cylinders - difficult in first gear and right up to 4th - not needed 5th !

Today after studying the excellent "How to", I spent some hours on it - cleaned the EGR valve (fairly coked but not too difficult to remove from inlet manifold), throttle body and boost sensor (both covered in oily soot).
The butterfly moves fine with no sticking (no position sensor on this car). Checked all the vac pipes and the big air hoses on top of the engine and back up to the throttle body.
Rebuilt it and took it out for a drive and it was definately faster / smoother until at 4 - 5 miles - on came the spanner and I struggled home.

I'm pretty sure that something happens when the engine warms up - anybody know anything about the engine management logic ?
It's like something is not being done or checked until a given temperature.
Much appreciate any advice.
Cheers
PFJ

[Celes]

Read the codes mate. It will point you in the right direction.

[the_wave_rider]

Have the same prob with my dti normally happens if I boot it in 5th i just turn the ign on/off as I,m driving and carry on. It doesn,t happen that often maybe 1 or 2 a month so never been bothered with it too much, I did check all the boost pipes for splits.

Its worth investing in a code reader as a couple of trips to someone else to read it and you have basically bought one

[Dazzy2006]

I had the same sort of problem when my car was cold it was fine but once it was upto temperature i got the spanner and limp home

Turned out it was the egr valve which was replaced and cured it, the egr does fail sometimes and cleaning it isnt enough as mine was pretty clean but still broken.

I would get the faults codes read and i think u may still find the egr has a problem

[Keithy]

yes try cleaning your egr, also give the boost sensor a clean. They are prone for gunking up

[Dazzy2006]

I'm pretty sure that something happens when the engine warms up - anybody know anything about the engine management logic ?
It's like something is not being done or checked until a given temperature.

PFJ

Missed this bit - i asked exactly the same question when mine went in for diagnostics and was told the ecu doesnt communicate with the egr until the engine is up to temperature

[pfj]

Finally borrowed an Opcom and read the codes (tried OBD2 scanners but they don't work on the early Vec-C DTis).
Cleaned the EGR and boost sensor - car runs very well until the coolant temp reaches 70-80C - then spanner comes on and it is extremely slow - slower than limp mode !
Opcom gave 2 codes :-
P0340 - Camshaft Position Sensor Circuit Malfunction (FA) - Present
P0335 - Crankshaft Sensor Circuit Range/Performance (FD) - Present
Further info from Opcom :-
The ETC Limp Home Mode (Electronic Throttle Control) remains "inactive" ie. unchanged by spanner but ...
Service Vehicle Soon (SVS) Indicator goes from off to on (as expected)

I have tried all this several times - it really does only happen as the engine reaches normal temp - why should the cam and crank sensors only be looked at when hot ?
Any ideas welcome
PFJ

[pfj]

I changed the crank sensor - easy to find on the front of the block under the oil filter.
Hardest part was cutting off the old cable ties - did not want to cut the sensor cable.
Drove car 14 miles yesterday and 20 today without any problems so far.
Warmed up to >90C and under these conditions - the spanner would have been on with the old crank sensor.
Cost £30 for Bosch part (Euro Car Parts trade account).
Cleared codes with Opcom and so far - they have not returned.
Planning a 50 - 60 mile trip on Saturday - fingers crossed.
Still have not seen a cam sensor and it is looking like the crank sensor only has effect when engine warms up.
pfj

[AKeeNShoT]

i have found this post most helpful, do you know what the opcom model was?

[nomad51]

does anyone know how much it is to replace the EGR?