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1.6 Tdci Overboost Problem, Map Maf Egr Sensors Etc . Intake Manifold - Missing Cover?


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#1 rikochet1967

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  • Ford Model: Focus MK2 1.6tdci
  • Year: 2005
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Posted 05 September 2011 - 02:14 PM

Car - 05 reg, 1.6tdci, 88k miles, owned from "nearly new"

I've looked through this very useful forum and may others in relation to turbo, MAF, MAP, EGR issues on the 1.6tdci and have read about all the problems identifying and fixing etc

Anyway, I am getting the "engine system fault" message and managed to get my local independent garage, which me and my wife use regularly, to have a look at it at short notice eventhough they were busy. They haven't managed to fix the problem, but reported that the error code(s) were to do with "too much overboost" and have done the usual checking of pipes etc.

They have advised me to bring the car back in about a weeks time when their "diagnostic/electrical" specialist is back from holiday so that he can have a proper look at it,

Over the weekend armed with some knowledge gained from forums and a purchased Haynes manual, I went about checking the engine over myself and:

1. changed the dirty air filter
2. cleaned the MAF sensor - there was some oil on the inside of the casing
3. added some Wynns injector cleaner
4. disconnected the battery overnight

On road testing, the car seems to be as smooth as before running through the gears without overloading until I'm hitting 50-60mph when I "floor it" to get bit of boost for overtaking etc ie. fault message and limp mode - although I can still get to 70mph (slowly).

On further inspection and reading about the MAP sensor on the intake manifold, I have noticed what looks like a missing cover near the MAP sensor - could this be the cause of the overboost problem?

Posted Image

This is very annoying since the car was running really nicely (too nice?) since I had the timing belt changed about 1 month ago.

Any help much appreciated, especially since this is my first post.

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#2 mintalkin

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  • Ford Model: mondeo tdci 130
  • Year: 2006
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Posted 05 September 2011 - 02:34 PM

i can not say about the cover,perhaps a focus owner can help you there, but some more Common causes of overboost are, sticking vanes in the turbo,faulty vacuum/vent pipes, a faulty actuator/wiring or a faulty pressure sensor.

#3 nickotdci

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Posted 05 September 2011 - 07:08 PM

By the looks for things there should be something bolt up to the oval shaped plastic thing, if that make any scene to ya???

#4 stevoyorke

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Posted 25 October 2011 - 07:43 PM

hi i am getting excatly the same problem as you are having,ford garage are not being too helpful but wanting me to book the car in at 80 quid per hour till they find the problem!!
have replaced my map sensor, no different, ford did tell me the MAP and MAF sensors were fine, having searched the internet, a possiblity is the EGR valve having become sticky, have had the RAC inspect the car, came up with fault code p0069, like you say split in hose or air getting in causing an overboost but not found any such thing yet, having looked myself many times too.

have you had any progress on yours what the problem was?

cheers

Car - 05 reg, 1.6tdci, 88k miles, owned from "nearly new"

I've looked through this very useful forum and may others in relation to turbo, MAF, MAP, EGR issues on the 1.6tdci and have read about all the problems identifying and fixing etc

Anyway, I am getting the "engine system fault" message and managed to get my local independent garage, which me and my wife use regularly, to have a look at it at short notice eventhough they were busy. They haven't managed to fix the problem, but reported that the error code(s) were to do with "too much overboost" and have done the usual checking of pipes etc.

They have advised me to bring the car back in about a weeks time when their "diagnostic/electrical" specialist is back from holiday so that he can have a proper look at it,

Over the weekend armed with some knowledge gained from forums and a purchased Haynes manual, I went about checking the engine over myself and:

1. changed the dirty air filter
2. cleaned the MAF sensor - there was some oil on the inside of the casing
3. added some Wynns injector cleaner
4. disconnected the battery overnight

On road testing, the car seems to be as smooth as before running through the gears without overloading until I'm hitting 50-60mph when I "floor it" to get bit of boost for overtaking etc ie. fault message and limp mode - although I can still get to 70mph (slowly).

On further inspection and reading about the MAP sensor on the intake manifold, I have noticed what looks like a missing cover near the MAP sensor - could this be the cause of the overboost problem?

Posted Image

This is very annoying since the car was running really nicely (too nice?) since I had the timing belt changed about 1 month ago.

Any help much appreciated, especially since this is my first post.



#5 stevoyorke

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Posted 25 October 2011 - 07:51 PM

looked up EGR and it's function and forums, its a problem in these diesels to become sticking and causes slow driving without any real acceleration, the drive home mode coming on! i ve noticed in the mornings when i start the car and gently very lightly press the accelerator, the warning lights stays off, engine smooth, when i start to put my foot down abit more further down the road, the warning lights up! and still smooth running.. feel EGR needs looking at, next check for me.

By the looks for things there should be something bolt up to the oval shaped plastic thing, if that make any scene to ya???




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