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Discussion Starter #1
So I have an 06 3L crd 100k on the clock and just recently my car went into limp mode...I have these codes:

P0401 EGR airflow insufficient

P0403 EGR circuit issue

P0046 turbo boost solenoid

Car has the red lightening strike flashing too.

So I have replaced the turbo boost actuator...I've removed and cleaned the EGR valve and I've took out fuse 11 and replaced it.

No fix...the car exits limp mode everytime I start it but as soon as I drive and reach 2000rpm, it jerks violently then goes into limp mode.

I'm stuck and need your help plz...

BTW I'll post a video...you will be able to see my EGR valve and you will notice the soot build-up...I didn't think it was too bad but you may know otherwise.

Cheers

Mick
 

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2 of the codes seem to suggest implausible voltages being detected....I dont suppose you've checked your harness for wear as the CRD seems to have a habit of shredding wiring insulation towards the rear of the engine?
 

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Discussion Starter #3
Yep checked correct...I've just ordered an endoscope so I can film down the EGR flexi tube to see if there is any blockages...I'll put a resistor on the EGR plug tomorrow...if it turns out there's no blockages and the resistor fails, then I guess it's a trip to a proper mechanic rather than my inexperienced hand...ouch that might be pricy.
 

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By default the EGR valve is closed so fitting the resistor as mentioned in the PM should sort it, you may get a code on and off mentioning airflow but it will not cause limpmode if you still have limp mode after it is likely another cause, is the turbo actuator moving freely when the ignition is switched on and off?

have you checked the resistor on the swirl valve to be sure that is fitted ok and not causing issues?
 

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Discussion Starter #5
Turbo actuator is moving freely...the waste gate veins move easily and smooth when the actuator is detached and the turbo sounds normal...when this problem struck the first thing I did was put a new turbo actuator on so I'm confident it's not that...I have a viezu remap so my car has often threw up a turbo boost fault code even though it works fine.

OBD2 points to the EGR. I'm definitely gunna try the resistor and if it removes the LHM then I'll go for a long motorway drive to burn off some carbon deposits then try the EGR valve/solenoid as normal, just for experimental reasons...I've decided that even if I do get it working I'm gunna run with a resistor anyway as I think it's better for the engine.
 

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Discussion Starter #8
So I did the egr resistor trick today and it took the car out of limp mode and the red lightening strike went away...?

I then went for a good drive on the motorway but the car was still jerking violently at 2000rpm and would not go over that rev range. I couldn't get over 70mph.

1 hr later car back in limp mode with new code P0234...

I switched the engine off, switched it back on and was out of limp mode with no red lightening but the car won't go over 2000rpm and jerks so bad.


I'm thinking I'll have to bite the bullet and go the stealer...right on top of Christmas too?
 

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but the car was still jerking violently at 2000rpm and would not go over that rev range.
the same symptoms i had when my actuator failed.
you say you have already replaced yours in the first post, the ebay ones, unless you find the exact same part number, are different.
i had my original unit fixed by ECUtesting in the UK. like new now.

and looking at the photo of your error codes

P0046 is T/Super Charger Boost Ctrl Solenoid Circ Range/Perf (re actuator)

P0671 is Cylinder 2 Glow Plug Circ
P0672 is Cylinder 4 Glow Plug Circ
P0674 is Cylinder 5 Glow Plug Circ
P0675 is Cylinder 6 Glow Plug Circ

4 of your 6 glow plugs have failed, do you have hart starting problems as well?

I also have a Viezu remap in mine.
 

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Discussion Starter #10
I checked my glow plugs and there all fine so I know the glow plug module is faulty. I'm told that's common on our cars.

I got my actuator from turbo developments in London and have confidence in them. My P0046 code has been a long standing intermittent issue likely coz of the remap.

Just learned something new today....I drove to work and never took the rpm over 1.800...still had a few bunny hops but no EML...got to work and plugged in my obd2 and the P0403 code was gone and the P0046 also good...the code P0401 was still present.

I'm booked in with my local mercedes specialists garage (my wife's cousin) so he's gunna run a full diagnostics...he reckons my EGR wiring is the likely issue.

He's only worked on a few 300c so he is interested too.

Codes on codes off different codes showing...???
 

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have you checked the wiring where it's stuffed under the aircon pipes for chafing/worn thru wires?

another common problem
 

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Discussion Starter #12
Yeah I checked and the previous owner actually put preventive measures in place to protect those wires...he did an excellent write up on how to do that so I know they're safe...his website is theduxs.com
On this forum he was Petman...
 

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Discussion Starter #13
Update and question.

I went to my cousins garage today. He ran a diagnostic check and we now know the turbo boost actuator works on command.

The egr acuator works but the egr valve test was inconclusive. (He needed me time)

All air intake hoses are safe and secure.

My car is now booked in with him for Friday when he will do a full investigation.

He mentioned my symptoms sound like a swirl port motor issue so I pointed out that I have a swirl port resistor.

QUESTION

Would the swirl resistor prevent his diagnostic computer from reading a swirl port fault?

I was using the EGR resistor so it didn't show any trouble codes when he checked the ecu. After the garage i drove home without the EGR resistor and the only code now showing is the P0403.

This is the most confusing error I've ever met...it has to be electrics but I just hope he can find it.

I drive a 300 and I couldn't even overtake a Ford KA earlier...I looked like a moron when I had to get back in lane haha
 

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Discussion Starter #15
Yeah he was shocked to hear there was restricted EGR flow in a car he owned hahaha...he advised I clean it and use my right foot with more oomphh...I didn't have the P0403 code then do he wouldn't know about that.

He never had issues.

I don't actually think I have a flow issue...I think the code P0403 relating to the electric circuit is the true issue and that triggers other codes when I put my foot down.
 

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Discussion Starter #16
So I checked the wiring under the cooler pipes and look what I found...I should have listened to you guys earlier...

I can't see any brakes in the wiring but I have green circled picture 1 to show you a worn wiring casing.

Would that be enough to throw up the P0403 code?

That wire is black but I don't see black wires in the egr...I don't know where thertmostat go in fact...

Hope jack sees this is know this is his field
 

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the casing wear isnt enough, but it IS enough to warrant you taking a look under it for breaks in the insulation of the wires themselves & to trace the full length for any other signs of interruption
 

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Discussion Starter #18
Cheers bill

Just noticed my spelling mistake...thermostat...that was meant to say...the rest in fact...predict text ya see...well its going the garage tomorrow so I'll let you know
 

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Discussion Starter #19
Mechanics diagnosis

Turbo charger failed...pitting veins/worn bearings/excessive play

Swirl port motor failed in open position... however, has a resistor deceiving ecu.

Mechanics explanation for the DTCs

The swirl port/intake shut off motor, the turbo actuator and the EGR valve all work together to create good flow through EGR system....the flow is not right as the turbocharger has failed but the swirl port resistor is deceiving the ecu into thinking all is normal...the egr and turbo actuator know otherwise and this is where the confusing codes on codes off have been registering.

Wiring is safe and I have caught the rubbing harness just in time.

I'm getting a delphi turbocharger for £650....a reconditioned swirl port with metal flaps for £200 and he's giving me 2 reconditioned manifolds for free as he's my cousin.

With labour about £1200 in total
 

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The swirl flaps are fitted in the manifolds with a plastic linkage so i don't understand what a reconditioned swirl port is unless it is the swirl motor you are referring to, i assume the reconditioned manifold have been cleaned and the linkage and flaps checked, however it is pointless refitting the swirl motor and flaps the engine will run better without them,
by the way the swirl motor is open by default so will be fine with the resistor fitted

If the turbo is knackered i would change that and check that the egr valve is closed in its default position and fit the resistor, again the engine will run better without the egr valve
problem is a Merc dealer tech will tell you you need them and charge stupid money for nothing.
 
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