gstuart · Jan 5, 2022

Hi

hope everyone is keeping well , wished to share this in case it may help other

so got a warning come up on the dashboard then limp mode , after driving it home plugged in the gap iid to get the following codes , other systems were engine vibration but only over 55 mph

Engine TDV6

P120F-00 (28) Fuel pressure regulator excessive variation
P0402-00 (68) Exhaust gas recirculation flow excessive detected
P0046-00 (28) Turbo/supercharger boost control solenoid - circuit range/
performance

after a lot of investigation I found a split in the air inlet pipe near the turbo , so got to remove the inner plastic wheel arch liner , plus will remove the intercooler metal pipe as going to replace the short turbo hose and allow me more room, well if u can call it room, as it’s still limited access , lol

few pics, sorry for the bad resolution as it’s just a cheap endoscope , new air inlet pipe turned up, am waiting for the new metal intercooler pipe seeing it’s coming out and not very expensive will replace it at the same time, already have the short silicone turbo hose, new clamps , also ordered new stainless steel bolts , along with the scavenger pipe

in the mean time I removed the throttle body , Map, Maf sensors and cleaned them , fitted a new MAP sensor seeing it’s the orginal , can see in the pics of the comparison of the new Map sensor having a larger hole , I also removed the ECM and TCM connectors to check all the pins

on live data I get “ Boost pressure actuator - Bank 1 N/A “ , plus “ Supplementary engine coolant temperature showing minus 40c , I haven’t been able to find out what sensor provides this data

so just waiting for the new hoses, currently is up on axle stands and wheel off , put a red X on the pictures of the items that need to be removed

will update the thread as I progress

gstuart · Jan 6, 2022

Plus out of curiosity has anyone heard ref a “ Supplementary engine coolant temperature sensor “ , plse

am wondering if it’s to do with the FBH, but alas for the life of me can’t find any details about this as mine currently shows -40c

on the off chance would anyone with a D3 be so kind to have a look on there live data please , also wonder if there’s a difference between the EU3 vs EU4

would be so grateful, many thks as always

gstuart · Jan 7, 2022

So ordered another stainless steel jubilee clip, the new hose came with one already fitted but that’s only 9mm wide, wanted one that was 13mm wide as wanted it to secure the hose better onto the turbo

Plus as I’ve got to take out the metal intercooler pipe have ordered a new one as well , that way all the pipes and silicone hoses plus clips will all be new, all the clips will also be stainless steel including the T bolt clamps

yep, I need to get out more, , lol

Nodge68 · Jan 7, 2022

gstuart said:
Plus out of curiosity has anyone heard ref a “ Supplementary engine coolant temperature sensor “ , plse

Hi Gary. Good to see you.

Could it be the oil temperature sensor?, or do you have a reading for that?

gstuart · Jan 7, 2022

Nodge68 said:
Hi Gary. Good to see you.
Could it be the oil temperature sensor?, or do you have a reading for that?

hi mate

Hope ur ok and many thanks

Indeed have a reading for the oil temperature sensor , is above in the live data , also got these readings , just weird this Supplementary engine coolant temperature reading minus 40c

the “ Boost pressure actuator- Bank 1 showing N/A I assume is a bad wire , have double checked the movement of the turbo actuator arm for full movement and also sprayed nearly half a can of silicone spray on the arm as I moved it ,

also been looking on the wiring diagrams , think the split in the hose once replaced I’m hoping should cure the limp mode - over boost

removed the throttle body , replaced the Map sensor , only because it was the original and the new one has a larger hole , also fitted a new air temp sensor as the old one was broken, egrs are blanked , removed the short pipes at the throttle body, new O rings and sealed them , cleaned Maf as well , getting readings from all of the sensors via live data

do have a smoke machine as I’m wondering if it would be a good idea to check the intercooler and air intake pipes after I’ve replaced them

Also wonder if maybe the turbo actuator arm has to touch a microswitch being that wire that’s showing N/A to send a signal back to the ecm , alas I’m not sure how it gets that signal

maybe the turbo actuator arm wasn’t moving the full travel , have had all the connectors off the ecm and tcm , as worried of broken pins, all ok , however did get a multitude of TCM errors after removing the connectors , will take them back off and give them a good clean with contact cleaner

apologises I’m waffling , lol, , think my next step will be to replace those intercooler / air intake pipes , then give it a run down the road with the engine up to temperature , then re read any DTC’s and if that N/A is still there

Don’t know if the signal wires are the VGT ones shown on the ECM

as always many thks

Nodge68 · Jan 7, 2022

gstuart said:
Indeed have a reading for the oil temperature sensor , is above in the live data , also got these readings , just weird this Supplementary engine coolant temperature reading minus 40c

Generally -40°C would mean a sensor is out of spec (failed, unplugged, broken wire), but some diagnostic software also applies this -40°C to a value that doesn't exist on the data steam, which is probably the case here.

There's only 2 temperature sensors on the D3, one for the coolant, and another for the oil.

gstuart · Jan 7, 2022

Nodge68 said:
Generally -40°C would mean a sensor is out of spec (failed, unplugged, broken wire), but some diagnostic software also applies this -40°C to a value that doesn't exist on the data steam, which is probably the case here.

There's only 2 temperature sensors on the D3, one for the coolant, and another for the oil.

many thanks and very grateful, must admit that’s what I thought ref a sensor unplugged etc, checked everyone that I could find to no avail,

main issue is I couldn’t find any reference to this Supplementary engine coolant temperature, looked through all the manuals as well

as always very grateful for the help

gstuart · Jan 9, 2022

So done a little bit more today , just found it easier spending a few hours each time

Got the wheel arch, inner wheel arch liner out, short turbo hose removed and metal intercooler hose unbolted , alas can’t get it out yet

looks as though I’ll need to remove the fan cowl assembly and fan itself , must admit never had to remove the fan before , hope it’s not to difficult to undo

few piccies , luckily the rusty looking bolts all come undone, took well over an hour because they were hard to get a socket , did recently get a Milwaukee ratchet which I must say really pleased with, wanted one for ages and made life a lot easier as I used a long socket bar to u do all the jubilee clips , etc

so next job will be that cowl and fan and go from there in getting that metal intercooler pipe and air inlet pipe which sits underneath , enclosed a pic of the metal pipe that I’ll be replacing

laslty managed to get the horrible clip off, haven’t got a clue what kind of pliers is used, however I’ll replace it with a stainless steel jubilee clip as don’t want to mess around because it’s in such a tight space

Dippypud · Jan 9, 2022

That last pic of the vehicle, is that damage to the metal work, looks like a small 'cut' or piercing ...a sort of halfmoon shape ...

gstuart · Jan 9, 2022

Dippypud said:
That last pic of the vehicle, is that damage to the metal work, looks like a small 'cut' or piercing ...a sort of halfmoon shape ...

View attachment 256275

bless u I’ll have a look, know I had to use a small angled hose lever as the hose was stuck fast onto the turbo ,was a right pig to get off , found a pic of the tool I used

thks again and a very sharp set of eyes

Dippypud · Jan 9, 2022

gstuart said:
bless u I’ll have a look, know I had to use a small angled hose lever as the hose was stuck fast onto the turbo ,was a right pig to get off , found a pic of the tool I used

thks again and a very sharp set of eyes

View attachment 256279

I get paid extra for doing just that at work, catching things before they get too far down the line ... then we can fix it ...

gstuart · Jan 9, 2022

Dippypud said:
I get paid extra for doing just that at work, catching things before they get too far down the line ... then we can fix it ...

in that case I’ll put the kettle on so I can then watch how it should be done

gstuart · Jan 9, 2022

May i ask please what’s the name of this clip and what pliers are used for them plse, many thanks

marjon · Jan 9, 2022

gstuart · Jan 9, 2022

marjon said:
J

ur a legend , thank u so much

yikes £60.00

gstuart · Jan 9, 2022

Funny enough I did get a set of pliers but soon realised they wernt for this type of clip, in the end I struggled like hell with some pincers

don’t mind buying a dedicated set of pliers though if it saves me the headache, particularly in such a restricted confines around the turbo area I’m currently working on

gstuart · Jan 10, 2022

So was going to replace the metal turbo intake pipe , however after kindly been advised seeing it’s stainless steel there’s no point removing it

out of curiosity I looked in the workshop manual, have to remove the PAS pump and upper wishbone , so indeed will just clean the junk off the ends and reuse it

In a few days time I’ll try and get the fan and cowl out as I’ve got to get the air intake pipe out as that’s split , fingers crossed I don’t have to take anymore parts off to gain access for its removal , lol

Nearly got everything , new air intake pipe , T bolts, silicone intercooler hoses , new stainless steel nuts and bolts , just waiting for some wider jubilee clips as the old one is 9mm and ordered a 13mm so will clamp better on the turbo air intake pipe , yeh i know , I need to get out more , lol

gstuart · Jan 13, 2022

So now finally have wider jubilee clip, plus the new one is stainless steel , with it being wider should clamp the hose down better than the old narrow one , yeh i know I need to get out more, lol

marjon · Jan 13, 2022

gstuart said:
yeh i know I need to get out more, lol

you can when the cars fixed

At least you know it’s a done proper job

J

gstuart · Jan 14, 2022

marjon said:
you can when the cars fixed

At least you know it’s a done proper job

J

Thks buddy and indeed just wish to ensure that I’ve covered everything so in theory I know it’s all done and dusted , I remove the throttle body, egr pipes , Map, Maf , air temp sensor to ensure they were all clean , did fit a new Map sensor as the new style had a bigger hole so thought it won’t block up as easy as the older type , plus got a new air temp sensor was broke at the connector

took a picture of them side by side as a comparison , did treat myself to some plastic clip pliers as it drives me nuts every time I try and remove them, at least now it will be an easier job

the new impact wrench and ratchet I was really pleased with and certainly helped get some of the bolts / nuts removed , as a side note when I was doing some timber work did get a new impact driver, first one I’ve owned and my god what a difference driving screws into wood etc

sorry I digress , plus I did remove all the connectors on the ecm and tcm, now got a long list of TCM errors , so I’ll have to remove the connectors again , give them a good spray with contact cleaner and also use the new terminal files I got

Im pretty sure I now have everything I need m ie, air intake pipe, stainless steel genuine jubilee clips , Stainless T bolt clamps , silicone intercooler hoses , etc

fingers crossed Sunday will be nice, apologies as I’m waffling again as per usual, lol

thks again and will update the thread as I progress , few piccies