EGR system.

[emma & ian]

Hi everybody.

I have a new shape bongo 2.5 diesel V reg 1999.

After hours of fault finding I have found the EGR position sensor is faulty causing the glowplug light to flash and reduce power via the turbo wastegate.

I have tried blanking off the system but due to the elctronic sensor fault it still reduces power.

My question is: Is there anyway of fooling the ECU into thinking the egr position sensor is working and blanking of the egr system or do I have to find a new sensor.

The problem with the sensor is it should have a resistence of 4.5-5.5kh but is reading 8-9kh.


Any advice would be much appreciated as we're hoping to go away at the begining of June.


Thank you.

Ian.

[The Great Pretender]

Fit a resistor to bring it within limits?

[dandywarhol]

Agree

[emma & ian]

Update.

I have replaced the EGR valve after checking it had the correct resistance. Had it running for 10-15min then light started flashing again.

I have read some of the other posts to do with older type systems & read about someone replacing the vacume hoses, so that is my next job.

I'll let you know tomorrow how I get on.

Fingers, toes, arms, legs & eyes crossed.


Thanks.
Ian.

[emma & ian]

Update part 2.

I have replaced all the vac pipes to the EGR sensors/switches etc.

Ran for a while, looked promising.

Warning light now flashing but it is a different code.

0510 Closed Throttle Position Switch

The throttle pedal has 2 switches on it, 1 is like a plunger type similar to a brake light switch with 2 wires, the other is at the top of the pedal & is sort of circular with loads of wires coming out.

Does anybody know which of any of these could be the throttle position switch?

Has anybody had this fault before if so did you manage to fix it?

Thank you
Ian.

[The Great Pretender]

As you have had no response I will have a stab at helping.
Disconnect the plunger switch and put a meter on it to see what it is doing, although I dont have a clue what it is for. The circular one could be a variable resistor (throttle potentiometer) to send information to the fuel pump if it is fly by wire.
Thinking about it, the plunger switch could be a backup if the fly by wire has a problem, so it tells the ECU that the loud pedal is on or off for limp mode. Just guessing though.
Try disconecting all the plugs on that side of the system and spray them with switch cleaner before spending more money.
Good luck...........................