EGR on W211.220 E280 cdi Estate 3 litre V6 OM 642.920

[Adrian Montagu]

I am getting these results with an iCarSoft V2 tester.
Issues

2511-1
State Current
Check Component Y27/9(Left EGR Positioner)
Position signals fault

This is P0404 and is reporting 5% and not changing with revs
---------------------------------------------------
2355-2
State Current
Check System “Exhaust Gas Recirculation Control”
Air Mass is too large

This is P0401
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2647-1
State Current
Check Component B2/7(Right Hot Film Mass Airflow Sensor)
Value is above limit

This is P0101
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This is after I have installed a new Air Mass Sensor
I have also replaced the Up-Stream O2 Sensor on driver’s side which was faulty.

I thought that there was only one EGR valve.
Where is the LEFT EGR positioner or is this a description error?
Sticking on 5% would seem to me that the EGR is blocked or clogged and fixing it in one position.
Exhaust Gas Recirculation Control - is this the valve control mechanism not able to cope with the exhaust with only 5% open?
As I have replaced the Air Mass "Y piece" with its two sensors. Why would I still have this showing up?
I have reset all the faults but they return.
I propose to remove and clean the EGR valve
Any comments or ideas anyone?
Adrian

 

[kenneth kyle]

Clean the egr but check the intake port motor also after,it sits between the intake manifolds

Sent from my SM-G900F using Tapatalk

 

[Adrian Montagu]

Hi Kenneth,
Thanks for your advice.
"Between the intake manifolds" Is it located forward or backward on the engine and is it easy to get to?
Any tips on locating it more specifically.
Your help is really appreciated.
Regards
Adrian

 

[LostKiwi]

Directly beneath the turbo intake/batwing seal.

 

[kenneth kyle]

Just under the diesel filter,but pls check actual values also for other different sensors before stripping please

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[Adrian Montagu]

Thanks Kenneth,
I will undertake this over the next week weather permitting.

 

[Adrian Montagu]

Thanks LostKiwi,
Appreciate your advice.

 

[Doug1234]

Remove plastic cover from front of egr and you can operate it by pushing down on the arm.. it wont be stuck on 5% its just a number it seems to come up with when code is thrown, my Jeep with om642 would do it and egr was closed tight.
I would get p0403 with an icarsoft bcii jeep specific reader , but if I used the generic obd side of reader it would give me p0404.
My Jeep had other problems which caused the egr to flag up.
You are also getting mass airflow above limit, mass flow above limit is going to upset ecu which is why you are probably getting egr code… sort the mass air flow out first and then chase down the egr if it still exists.

 

[supernoodle]

Would you not get a mass flow high if there was no EGR? At a given operating point a certain rate of EGR is expected, if that isn't realised (EGR closed/blocked), the cylinder still has to be filled, which can only be the metred air. So it will be taking in more metred air than mapped.

 

[Adrian Montagu]

Supernoodle,
Those were my thoughts too but I was unsure. Good to have someone else thinking the same way.
Thank you for your help. The wife is driving to Newcastle in it at the moment so it will be a slow drive if the Limp home mode cuts in. (It sometimes clears itself). When I get my car back I will set to work.
Thanks once again
Adrian

 

[Adrian Montagu]

Hi all,
At last I have had a chance to deal with the EGR. No problems removing it. Gently tapping it each way seems to free it off. The business side of the valve looked as expected with mild carbonisation. It is what I would expect it to look like. I removed the cover as Doug1234 specified and found the mechanism free to move. Thus I surmised it must be an electrical fault with the unit. I bought a new unit for £148 and installed it. So far, no limp home mode and no reduced power. I have yet to check the diagnostics to see what has happened to the other items mentioned. - Next free moment. Thank you all on this one.

 

[Wighty]

Hi all,
At last I have had a chance to deal with the EGR. No problems removing it. Gently tapping it each way seems to free it off. The business side of the valve looked as expected with mild carbonisation. It is what I would expect it to look like. I removed the cover as Doug1234 specified and found the mechanism free to move. Thus I surmised it must be an electrical fault with the unit. I bought a new unit for £148 and installed it. So far, no limp home mode and no reduced power. I have yet to check the diagnostics to see what has happened to the other items mentioned. - Next free moment. Thank you all on this one.

Good fix for that price , fingers crossed .

 

[Botus]

that's a very good price - brand new genuine or ?
removing the cover - was a new one on me is it designed to come of or brute force and abuse ? Its odd yours came out my fathers doesn't EGR doesn't move at all and the indy I spoke to said some are so tight they nearly destroy the car trying to get them out.

what miles out of interest ?

 

[Noddy 99]

that's a very good price - brand new genuine or ?
removing the cover - was a new one on me is it designed to come of or brute force and abuse ? Its odd yours came out my fathers doesn't EGR doesn't move at all and the indy I spoke to said some are so tight they nearly destroy the car trying to get them out.

what miles out of interest ?

Hammer. Chisel. Effort. Stamina.

Saw a bloke on Tube do it by loosening the bolts and then revving the engine. Didn't work for me.

 

[Adrian Montagu]

Hi Botus and Noddy,

I used an unorthodox method to remove to EGR; I warmed the engine slightly first. A one inch wood chisel laid flat against the fixed part with the sloping part against the valve. Tap gentle until separation is achieved. Use some wd40 in the gap. Then with a piece of steel rod and a hammer; gently tap either side to cause rotation. The emphasis on all of this is "gently".

This is the link for the EGR valve:- https://www.ebay.co.uk/itm/274889916489?hash=item4000b74049:g:bHgAAOSwiAJhCSfi it is a chinese clone so you do take a chance. It looks well made. Maybe the originals are made in China.

One cover comes off to reveal the mechanism. The other I tried but decided that I would do damage.

Miles 197,000

Hope this helps,

Regards

Adrian

 

[Doug1234]

I have seen a video on Youtube where a guy made a tool up… he had two dowel pins to fit into the bolt holes on egr and then some strap steel to which he added a 3 foot long handle and then welded the dowels onto it and he could then gently tease the egr out with minimal effort. Sadly I have looked but cannot find video.
As any of you know to remove it you use gentle force and it comes out easy.. go hard on it and it will not move.

 

[Noddy 99]

Mine was impervious to gentle force; it laughed in my face.

I had to go at it like a Ukrainian miner...

 

[Botus]

Thanks Adrian,

I just wanted to pull to clean before burning it out - my next step is to fit longer bolts and bottom them out and go for a drive

tried heat and persuasion, it just laughs - didn't know you can get at it with a cover off - I now wonder if my 3 ltr 50 50 water meth mix ingested over 25 mins blipping the throttle would have been even better had I manipulated this - it was interesting - didn't seem to do much till 15 mins in, then all manner of crude came out the exhaust and it smelt like parafin for 5 mins - been ok in the 2 yeras since I tried

 

[Wighty]

Hi Botus and Noddy,

I used an unorthodox method to remove to EGR; I warmed the engine slightly first. A one inch wood chisel laid flat against the fixed part with the sloping part against the valve. Tap gentle until separation is achieved. Use some wd40 in the gap. Then with a piece of steel rod and a hammer; gently tap either side to cause rotation. The emphasis on all of this is "gently".

This is the link for the EGR valve:- https://www.ebay.co.uk/itm/274889916489?hash=item4000b74049:g:bHgAAOSwiAJhCSfi it is a chinese clone so you do take a chance. It looks well made. Maybe the originals are made in China.

One cover comes off to reveal the mechanism. The other I tried but decided that I would do damage.

Miles 197,000

Hope this helps,

Regards

Adrian

That’s what I did first time as well , worked a treat.