Hi all...

Today my 2002 1.8 tddi cut out and wouldn't start. Not a single sound when I turned the key. I bump started it, and it was really stuttering cutting in and out and after a min or so I could drive for a few mins. It cut out again but restarted luckily.... It didn't just suddenly die, just kind of lost response and power but most of the time it start working again.

The garage done all diagnostic checks, checked battery ,alternator and all connections and earth's. Of course it behaved perfectly in the garage. 

 

The only fault codes where 2 egr related. 

So after looking later when it started working normally again I noticed the 3 wires that should be in the connector on the egr where all completely out and bunched together.... So i separated them and the car drives perfectly now.

Ambient able to just insulate the 3 wires and keep them so they can't touch?

Or will that kill the car?

 

Any help much appreciated and thanks in advance!!

Sorry for the mega long write up! Pic attached

Hmm. no response at all on key turn suggests dead battery or immobiliser problem.  Immobiliser wont cut the engine if already running though.

Bad of your garage not to spot that those 3 wires have been yanked out of the connector; though they look pretty clean so may have been recently done...?

Basically, with the wires out, the car isn't getting any signal at all from the egr.  Too tired to think my way through if this means fully open or fully closed, but if unplugging it solves your problem, the egr is likely to be the cause and then probably choked up with crud.  You could try taking it off and cleaning it but its a helluva messy job... 

Thanks for reply. My only thoughts where the error codes for egr where because it wasn't wired in.. and the cutting out etc was because the 3 wires where touching and shorting out or something.

The only people who have been under the bonnet are me and the mechanic, and I've had the car over a year so I don't think they where pulled out but i agree they look like they may have been!

If anyone has the same car could they please take a pic of what order the wires go into the connector?

Thanks

Edited February 7, 20188 yr by Scratch1

Well the car is still running perfectly with those 3 wires out and not touching each other...

I would love to know what order they go into the connector so I can put them back and see what happens if anyone can help

I tried searching but colors don't seem to match many but it looks like they are sitting as they came out. If you're leaving them out just now I would cover the ends with some electrical tape.

3 hours ago, Scratch1 said:

Well the car is still running perfectly with those 3 wires out and not touching each other...

That is a vacuum operated EGR, and the three wires will be for a valve position sensor, probably just a pot. Some tests with a mutimeter might show some info, I would guess one wire is near earth, one about 5v, and one may be floating or near 0v or near 5v.

And on the valve, two pins should have a constant resistance between them regardless of valve position, and the third pin will vary as the valve moves. The varying pin is the signal, to connect to the floating wire, the other two would be trial and error (only 2 ways) to determine which way to connect.

But all that is a bit complex, the Mk2 1.8 TDCI does not really care if the EGR works, and from what you say the 1.8TDDI does not bother either. It could well be that the 5v signal also goes to other stuff, more critical. So the short circuit would be very bad news, Just insulate the wires, and see how it goes. Lack of EGR will do no harm, many people say it is a positive benefit!

The other thing that could be done is to check if the EGR is shut normally (no vacuum), and to disconnect & plug the vacuum hose. Then the (unmonitored) valve will not open and cause smoke and loss of power.

In this weather, I would do the minimum to keep it working, then sort out the details later when it is warmer!

 

Thank you for the reply, I actually live in Spain so weather isn't too much of an issue! I think it was originally a German car from new and now on Spanish plates. But I guess under the bonnet is identical. If my best mate from England was here what you explained would be done but I'm far less on the know than him. I'll insulate the wires and see how it goes. Thanks very much to you both for the help!