3.0cdi EGR fault, nothing seems to work

[Gurkus]

Hello, I am desperate and can't find any solution to my problem.
I have Chrysler 300c 3.0crd 2006, it's the same engine as many mercedes sprinters, C, E class has. Om642 3.0cdi engine.
After quick acceleration to about 90km/h, like, genuinely pedal to the ground, a red bolt turns on in the instrumwnt cluster and the car goes in limp mode, sometimes before that it starts to lag. But if I accelerate slowly to 90km/h, I can drive for about 20km and only then the fault turns on. Nothing happens if I accelerate quickly im city, but if I drive for about an hour in city, then it did turn on for me twice. Seems like something warms up a lot and then it turns on. Diagnostics say that its egr fault p0403, I replaced egr valve - nothing changed. I changed EgR pressure sensor, still nothing. I'm wondering about o2 sensor, do these engines have titanium or circonium o2 sensors? Computer says that at idle it's 1.5v and when accelerate - can go up to 3v. I know that titanium o2 work up to 5v,so I'm not sure what could be the problem, because diagnostics doesn't show any mistakes about my o2 sensor.
Any suggestions? Please! And thank you!

 

[Doug1234]

I have the Jeep GC (06) with the same engine.
Look for boost leaks ,although its the same engine the software ie Mercedes it is a bit different like for instance you do not get specific injector misfire codes with Jeep
Check the main engine wiring harness from the fuse boxes where it goes to the engine as it can rub through on the air-con pipe and cause all sorts of weirdness .
Red lightning bolt on dash is normally reserved for either egr or swirl flaps.
I have a Jeep specific Icarsoft bc2 and I can plug it in and scan and retrieve any codes , using a mates everyday obd reader finds nothing on mine.
Also the code you had for egr I would expect a few more codes to have come along for the ride.
Has it got a dpf ?, my Jeep hasn't as they did not fit them until 2008 or a bit later.

 

[Gurkus]

I have the Jeep GC (06) with the same engine.
Look for boost leaks ,although its the same engine the software ie Mercedes it is a bit different like for instance you do not get specific injector misfire codes with Jeep
Check the main engine wiring harness from the fuse boxes where it goes to the engine as it can rub through on the air-con pipe and cause all sorts of weirdness .
Red lightning bolt on dash is normally reserved for either egr or swirl flaps.
I have a Jeep specific Icarsoft bc2 and I can plug it in and scan and retrieve any codes , using a mates everyday obd reader finds nothing on mine.
Also the code you had for egr I would expect a few more codes to have come along for the ride.
Has it got a dpf ?, my Jeep hasn't as they did not fit them until 2008 or a bit later.

It had dpf buy it has been taken out and programmed out. I know that when the bolt turns on, EGR opens up to 5% and stops there. And also o2 voltage goes up to about 4 volts.

 

[Doug1234]

You have changed the valve itself so you can rule that out, give the wires a good look over as the code p0403 is for egr wiring circuit malfunction... meaning either the valve motor itself is bad or the wiring to the valve.
https://www.700r4transmissionhq.com/p0403-chrysler-300/

 

[mattkh]

What is the mileage?
Check the wires to the O2 sensors for heat related issues.

 

[Gurkus]

What is the mileage?
Check the wires to the O2 sensors for heat related issues.

The wires seem fine, no visible damage.
I have no idea about the real milage. Odometer shows 220k, and international data says that this is about right. but in reality - the motor has been swapped, i have no idea when. I've had this car for 3 months now, it came from france

 

[mattkh]

The wires seem fine, no visible damage.
I have no idea about the real milage. Odometer shows 220k

Thanks. The motor may be different but I think the exhaust system may not have been changed. At that mileage, and without any service history, I would change the O2 sensors, unless you can feel that the wires are soft and newish.

 

[Gurkus]

It turned out that the problem was with fuel injectors. They were changed before i bought the car and weren't programmed into my car(they should be, i didn't know that) and they weren't made for my car, the fuel pressure in injectors was way bigger than it should be. The electrician programmmed them and the problem is gone. The car runs as good as new.

Not the first time when failing fuel injectors show different fault code.