Son's car a 2007 1800 TDCI.

It has been a bit low on power for some time and now engine malfunction light has been on for last 3 weeks.

Just noticed today that there are very heavy black sooty deposits in exhaust pipe, rear box had large hole and again black sooty deposits around hole,

Checked for faults with basic OBD device (using TORQUE App), only fault showing was "P0490 - Powertrain", web lookup came back with

"Powertrain - Auxiliary - Emissions control - ISO/SAE Controlled

Exaust Gas Recirculation "A" Control Circuit High"

Visually no sign of smoke as he drove away.

All ideas welcome.

PS any advice on PC based software for fuller analyse of faults.

Regards

40 minutes ago, pauljoanss said:

PS any advice on PC based software for fuller analyse of faults.

By far the best system for Fords is Forscan. It can read codes from just about all modules, initiate self tests on most major modules, perform service functions that usually needs the Ford IDS (garage) system, and log real time data while driving for later analysis.

Forscan is a powerful Ford specific system, Cost £15.00 for the interface. Needs a computer of some sort. (COM port, USB, Bluetooth or WiFi interfaces available). You will find a lot about ELM327 & Forscan on this site, which together provide a very comprehensive diagnosis & maintenance tool. James (jeebowhite) has done a nice guide: http://www.fordownersclub.com/forums/applications/core/interface/file/attachment.php?id=21196

Forscan works best on a Windows laptop, with a USB ELM. The Tunnelrat one (below) has been reported to work well by several people. Forscan is also available for iOS & Android for some tablets & phones.

For a USB ELM327 adapter, see
http://www.spanglefish.com/TunnelratElectronics/index.asp?pageid=516992

Wireless ELMs are also available (bluetooth & WiFi), but are often not as reliable as the wired ones. Also they are rare in the "modified" form which is needed to access the 2nd Ford bus system. This 2nd bus is the MS-CAN bus, and links all the car interior electronics like door modules, and the BCM (aka GEM). But a standard ELM will still work with all the Underbonnet Modules (PCM, ABS etc) and with the IC (Instrument Cluster).

For an bluetooth wireless ELM, which one user at least says works with Forscan, see the KW902: http://www.ebay.co.uk/itm/ELM327-KW902-Bluetooth-Scaner-OBD-Link-OBD2-Diagnose-Interface-Tester-white-UK-/281631334205

The Forscan programme is free (in Windows format) and you can get it from:
http://forscan.org/download.html

Note: Simply reading the codes can do no harm, and does not change anything. Just do not reset the codes (and you would have to ask the scanner to do this) if you are going to take the car to a garage.

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If the EGR is at fault, then the first thing to do is blank it off. This is really easy on the 1.8, and it works fine with the plate in. If the valve is jamming, or more likely, there are electrical problems in the actuator, the light will still come on even if blanjed. However, the valve will no longer affect the engine.

Excess soot and loss of power could be due to the EGR sticking part open.

The EGR actuator is easy to remove, test, repair or replace on the 1.8, but the valve itself is built into the inlet manifold, and is a real pig to get at. I have had lots of problems with my actuator, just bad connections inside it. I have had the P0490 code often. I did a report on one repair, though it needs a bit of updating now:

http://www.fordownersclub.com/forums/applications/core/interface/file/attachment.php?id=38763

 

 

Many thanks for all that info Peter. 

Will certainly look to obtain the software and link.

My plan A is to try Wynn's EGR cleaner, easy and cheap with some good reports.

Plan B will probably be to blank the EGR, but will this give MOT problems.

Plan C ???

Would be very interested to understand the mechanism whereby a faulty EGR produces soot in the exhaust.

Regards

10 hours ago, pauljoanss said:

Plan B will probably be to blank the EGR, but will this give MOT problems.

No.

I would be very surprised if the MoT was a problem. I have mine blanked for at least one MoT. If anything, it might help to reduce smoke, which is the only real test they do. Though the 1.8 seems pretty good, usually, on that test.

The purpose of the EGR is to reduce the amount of oxygen that is in the cylinder as the fuel ignites & burns. This reduces the peak combustion temperature, which slows the oxidation of Nitrogen to Nitrogen oxides (NOx). However it is a compromise, as less oxygen means more particulates (aka smoke), There is a "sweet spot", or optimum compromise where NOx is lowered without appreciable smoke. But go a little too far, too much exhaust gas, and you get smoke. This can soot up the exhaust. It will only happen at fairly high fuel rates, as a diesel runs very lean at idle and low power, and the EGR would not be able to reduce the oxygen level enough. So you would not see it at normal pull-away.

The other cause of soot would be engine oil. It is worth keeping an eye on that, if you are not already doing so. But the P0490 makes the EGR a prime suspect.

Peter, you are a fund of information, many thanks again.

I will report back here with results but maybe a few weeks.

Planning to carry out the Wynn's EGR cleaner treatment tomorrow but not sure how I can run engine at the required 2000 rpm while working on my own, any ideas?

Had hoped the Forscan software might provide a means but laptop playing up (Win 7, stuck in "preparing to configure Windows, do not turn off" for last few days)

 

Regards