14 minutes ago, Tdci-Peter said:

The 9.5kPa & 1.8kPa DPs look a bit high. Especially if the 3270 rpm test was on the driveway, in neutral.

All data was recorded while driving.

Will try the run on Saturday and record all the data suggested.

Strange thing though the turbo is back working fully with EGR valve disconnected (Blanking plate will be on Saturday) 

19 minutes ago, Tdci-Peter said:

 

Safety Note: Make sure the wire or laptop / tablet etc can not interfere with driving, and do not be tempted to look at it while moving!

I won't ha ha 

hello

I am at a loss now. I have blanked off and reconnected my EGR, went for a drive to find there was no boost at all, so I disconnected the EGR and the boost was fine.

Any idea as I have none. 

 

Also here are the pictures of the data on a run earlier.

19 minutes ago, Liam121093 said:

Any idea as I have none

At the moment I am a bit blank too!

Was that the electrical connector being removed? These cars do detect the flow through the EGR, and blanking can cause problems. Seems to vary from engine to engine on the DV6!

It is not just the EGR valve, there is also a throttle valve (aka anti-shudder valve) used in the EGR system.

Any error codes? I would be a bit surprised if disconnection did not produce an error, and possibly blanking will give one too.

Try with the EGR unblanked, and connected.

Going out now, may be Monday before I get back here. See what happens.

Peter.

I have tried with it un blanked and connected but turbo only lasts a few seconds. 

And yeah it's the electrical connector that I unplugged 

Only error codes are for the EGR being disconnected but turbo only works fully with it disconnected.

5 hours ago, Liam121093 said:

Only error codes are for the EGR being disconnected but turbo only works fully with it disconnected.

No codes at all, even with Forscan, when the EGR is connected? And lack of Turbo?  - Weird

Were the Forscan readings above with the EGR connected? It looks like there is some Turbo boost - I assume the readings are absolute, so around 14.7 PSI is no boost (atmospheric pressure). Got any comparable readings with the EGR disconnected?

The theory I am trying to make fit is this:

When the EGR is connected, the pcm knows, and will try to use it. However if it is blanked, or if it is faulty, or if the throttle valve is faulty, then the engine air flows will not be right, and the O2 sensor readings (if it has one) will not be right. So the pcm knows there is a problem, but can not be sure where, or what. And it is cutting the turbo boost to be safe.

When the EGR is disconnected, the pcm sees this straight away, as an EGR fault, and signals the error code. As this is a non critical part, it does not use the EGR, and continues full power operation, so full turbo.

But if it was cutting power, logically there should be an error code.

However, the software in these DV6 engines is rather peculiar. I think a lot of it was written by French engineers in the afternoons. That means after the extended French lunch break of excellent French cuisine, washed down by copious quantities of good French wine.

However Good Food + Good wine = Good Software is an untrue equation! (I have tried it! + -> -> )

 

Forscan should have PIDs for EGR position (EGRVP or similar), and throttle valve position ( EGR_TV or similar). That is probably the next step.  Below is another thread that started with DPF problems, then EGR problems (no error code when blanked, but faulty operation), and it was a stuck throttle or by-pass valve. It all got a bit complex, but some bits are similar.

 

15 hours ago, Tdci-Peter said:

No codes at all, even with Forscan, when the EGR is connected? And lack of Turbo?  - Weird

Were the Forscan readings above with the EGR connected? 

All readings are without EGR . And no codes.

Really strange plugged the egr in today and turbo was ok for around 15 mins then turbo died.... again.

So I disconnected it again 😞 and again turbo fully working.

Also my DPF says ash full in 249.8 miles so will be changing that soon.

 

Off topic but could anyone tell me where the !Removed! glow plug relay is I have looked and looked but everyone give different locations.

Simply put I think your DPF is goosed. The turbo is probably intemittant due to there being next to no or too much back pressure from the exhaust hence the turbo not spoiling up, either that or the vanes are not working properly and stuck open or closed.

Having said that when I rebuilt my turbo on mine with a CHRA cartridge it was still as flat as anything and no Turbo pressure at all, but that was down to the EGR valve being goosed and stuck open, once I replaced the EGR it was much better. I actually thought I had done something wrong as I thought that replacing the turbo would have solved it and it didn't matter about the EGR valve being goosed. I have since blanked my EGR and the car is fine and has been since.

9 hours ago, Liam121093 said:

tell me where the !Removed! glow plug relay is

You have probably tried this, But I found the picture below. R12.

Re: The turbo problem, I think egr valve stuck, or throttle valve stuck open are the most likely causes. There is also an intercooler bypass valve near the throttle valve on some DV6s. Where the plastic turbo outlet pipe curves around the turbo, there is a stub linking it to the return pipe from intercooler to inlet manifold, via this by-pass valve, if fitted. That could also be faulty.

EGR blanking will only work without problems if all the bits involved are in good working order. The bits (valves etc) are still used, even though they do not result in any EGR flow. And the pcm can detect non-working bits.

Oh, and glow plug problems have been known to cause reduced power mode on the DV6, in some cases.

I do have the little stub bypass valve anyway to test it ? 

1 hour ago, Liam121093 said:

I do have the little stub bypass valve anyway to test it ? 

I think it is fairly straightforward to remove the throttle valve & by-pass valve assembly. They are in the duct coming up from the intercooler, near the driver's side end of the Turbo.

First test is just to operate the butterfly vanes by hand, to check they move freely, and can't stick open or closed. One of these valves was stuck on the "weird idle" thread I listed above.

Forscan gives access to a pcm self test (2 I think, Key on - engine off, and key on - engine on). This may exercise the valves at some stage.  Various things whirred & clunked when I tried it on my car, but I did not see what.

Further testing could be done with a multimeter & power supply, but is quite a lot more technical.

 

Yeah I used forscan to self test all.

And if this is the the stub I have checked by hand and is working fine. (Sorry about pics) 

4 hours ago, Liam121093 said:

And if this is the the stub I have checked by hand and is working fine

The throttle valve is at right angles to that stub pipe valve, where the pipe comes up from the intercooler. I think I can see the electrical connector to it in the top of the top photo.

You did mention glowplugs. Worth checking them too, they have some odd effects on this engine.

 

Ok will check them when I can thanks Peter 

Right some more information.

P042F

This error stops the turbo working. As soon as I clear the code turbo is back.

I am going to remove the egr plate, the  engine will then be all connected as it should be with no add ons. Then will scan for codes and see what it says. 

3 hours ago, Liam121093 said:

P042F

This error stops the turbo working.

Is that a different code to the one you got with the EGR disconnected?

(I think you said the turbo worked when EGR was disconnected, but gave a code).

I am thinking that maybe the EGR is a bit of a red herring, the underlying problem is the high DPs from the DPF. But electrically disconnecting the EGR throws in a higher priority error, that over-rides the DPF problem, but does not cause reduced power (no Turbo) mode. ??

 

I thinks I might get shot off this car.

On way home I had assisted steering failure, no power at all not even to get to 5 mph, the only error code I can remember was P1934 vehicle speed signal problem.

My dial went haywire all dash lights on. I am so lost and wondering if it's cheaper to get another car 😭

22 minutes ago, Liam121093 said:

I had assisted steering failure, no power at all not even to get to 5 mph, the only error code I can remember was P1934 vehicle speed signal problem.

My dial went haywire all dash lights on

Instrument Cluster problem. Might be a bad connection where the connector on the back joins the pcb. 2005/6 Foci are very prone to it.

See: http://www.fordownersclub.com/forums/applications/core/interface/file/attachment.php?id=40491

It never rains but it pours!

I think you're right about getting rid of it!  Seems to be one issue after another on this car lol.

Looks like you've got a loose electrical connection somewhere now, either clocks or GEM I'd guess.

Would a loose connection cause no power fault ?

 

3 hours ago, Liam121093 said:

Would a loose connection cause no power fault ?

The bad connection I had on my 2006 IC was on the main HS-CAN bus. This bus carries all of the critical information between modules including pcm, abs (which senses vehicle speed), ehpas (steering), and the IC. There are almost no limits to the range of faults that failures in this bus can cause!

Then the IC is an interchange module, where the MS-CAN bus meets the HS-CAN bus. MS-CAN serves all the car interior modules, like doors, radio, parking aid, and the all important GEM (aka BCM, or passenger fuse box).

All modern cars (not just Ford) have these bus system. They are a big advantage, allowing sharing of information, and they permit diagnostic aids like Forscan to work, but they are also a critical weakness when they go wrong!

Put your Forscan system to work, it should pick up some CAN bus related DTCs (U codes), although they tend to melt away fairly quickly if not diagnosed soon enough.

 

I do have a u0073 in the IC module but people have been saying it's different things 

 

35 minutes ago, Liam121093 said:

I do have a u0073 in the IC module

DTC U0073: Control Module Communication BUS Off

That is the CAN bus. And the error is reported as being in the IC (Instrument Cluster).

Try tapping the fascia all around the IC, with the ignition on. If any changes happen, it will further incriminate the IC.

In my pdf (above), a simple resistance test on the CAN bus is given. And what to do next, if the IC remains a suspect.

Dpf is ordered. I think it has completely failed as since removing the Egr valve and cleaning it (it was clean) i then done a static regen.

i cleared all fault codes drove around for a few hours and no error codes except for the u0073.

As soon as the dpf arrives I will be fitting it (any tips) and will let you no after if the car is ok.

Liam48279 is my account on my laptop as could not remember my password 

10 hours ago, liam48279 said:

i cleared all fault codes drove around for a few hours and no error codes except for the u0073.

The change of ID did have me a bit confused for a while!

I thought I remembered the U0073 error, it was in your 1st post in this thread, just checked. I disregarded it then, those CAN bus errors do turn up on odd occasions, and can be caused by the diagnostic adapters.

A faulty adapter could keep making it come back, but I think you have used 2 different ones. If it keeps occurring, then it indicates a comms problem, consistent with the IC failure you saw. But it seems that has receded a bit now, and the IC is working. But keep an eye on it, and try to run Forscan asap after any event, to capture the most information.

I know practically nothing about the mechanics of changing the DPF. But make sure the DP hoses go back on with airtight seals. And you will need to run the reset learned values service procedure in Forscan after fitting it.

Good luck, I hope you are over the worst now. The comms error could be a connector or cable. If it is the IC, they are often repairable for a not too painful amount.