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Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 - Unresolved #

Posted by Matt Seabrook on June 3, 2013, 3:30 pm

Year of Manufacture *: 1999
Engine Size and Code *: 2.5 Diesel WL-T
( Optional ) Scanner Used: G-Scan
( Optional) Fault Codes: P0400 + P1228

This has had me going for a bit now and I don't mind admitting I'm struggling with it now. Had this vehicle dropped in by another garage for us to take a look at. The vehicle came in with a flashing glow plug light. The other garage had already changed the glow plugs.

I hooked up the scan tool and read the codes. P0400 (EGR recirculation A flow) and P1228 (Wastegate Failed open under pressure) both stored and if cleared the P0400 comes back first then the P1228. I think the P1228 is a result of the P0400.

I have removed and cleaned both EGR valves (there are two on this engine). I have blown through the EGR cooler and pipes going to the exhaust manifold all seem clear. I have cleaned out the pipe from the EGR valve to the inlet manifold and a section of the inlet runner that the EGR pipe fits to. I have checked the operation of the EGR solenoids and all look to be working correctly. The funny thing is I cant seem to find how the EGR is monitored for flow. One of the valves has a position feedback which is working just fine. What is really strange thing with the vehicle is that if I actuate both EGR valves when the engine is cold it will kill the engine with about -0.3bar of vac. When the engine is hot give both valves full vac and the engine will idle just fine as though the EGR is not working. If the pipe coming from the EGR valves is removed and the valves operated exhaust gasses flow when the engine is hot or cold.

I believe this is the same engine as the Ford Ranger so I hope that someone can help with this one.

Cheers Matt

Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #

Posted by Matt Seabrook <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3462' width='330' height='300' border=0 style='border:none;'> on June 5, 2013, 4:53 pm, in reply to "Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #"

I'm also struggling to find out how the ECU monitors EGR performance. I cant find a feed back sensor and there is no MAF sensor on this engine. Any body help?

Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #

Posted by Richard Endean <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2939' width='330' height='300' border=0 style='border:none;'> on June 8, 2013, 12:47 pm, in reply to "Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #"
Richard Endean

Like you, I'm wary of the fault code description. The glow plug light will give you blink codes on most Bongos. If you have an egr fault, it's usually down to damaged wiring at the back of the engine bay or a lack of vacuum from the pump.

Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #

Posted by Matt seabrook <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3462' width='330' height='300' border=0 style='border:none;'> on June 9, 2013, 7:09 am, in reply to "Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #"
Matt Seabrook

Thanks Richard for the reply I was feeling a little lonely until you posted

I have measured vac and all seems ok with that. Also one of the EGR has a position sensor and is reporting back 4.49 volts full deflection so that looks OK. The other EGR you can see the actuator going full deflection. The customer has the car back for the moment as I have put too much time in to this car already. It will return if the situation gets worse.

Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on June 9, 2013, 4:10 pm, in reply to "Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #"
Mark Carter

Hi Matt,

I don't have much experience with the above vehicle but I do know a man in Cornwall that specialises in them.

Would you like me to give him a call and see if he can shed any light on the issue or are you Ok to wait and see if it returns?

Regards
Mark

Modern cars, Its all wizardry and witchcraft

Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #

Posted by Matt Seabrook <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3462' width='330' height='300' border=0 style='border:none;'> on June 9, 2013, 8:50 pm, in reply to "Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #"
Matt Seabrook

Hi Mark

Hope you are well. I will see if the vehicle returns and I may well be in touch to see if you can find any more info for me.

Cheers Matt

Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #

Posted by aidan birley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2879' width='330' height='300' border=0 style='border:none;'> on June 9, 2013, 9:57 pm, in reply to "Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #"
Aidan Birley

Hi Matt

I have seen a ranger with a clogged MAP sensor, just A thought I wonder if a sluggish response from MAP may result in your codes.

Does this use a throttle flap to increase EGR ?

Just to prove how reliable the description is, Could you create a fault in the feed back circuit, just to see if it logged a circuit or flow code.

Cheers Aidan

Unresolved #

Posted by Matt Seabrook on June 10, 2013, 9:23 am, in reply to "Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 #"
Edited by board administrator December 2, 2013, 6:34 pm

Hi Aidan There is no flap in to boost EGR in this system. The map sensor could be slow to respond but is working. The boost sensor is the only thing I can find that could be monitoring the EGR.

Thanks again Matt

Re: Unresolved #

Posted by Scott Taylor on December 1, 2013, 9:31 pm, in reply to "Re: Ford Freda / Mazda Bongo 2.5 1999 - EGR low flow, codes P0400 & P1228 Unresolved"
Edited by board administrator December 2, 2013, 6:35 pm

Hi there we see this problem ALOT with the 400 chassis number bongos
This fault seems to be thrown up for a few different faults I don't think we have had 2 that have been the same fault

The first one was caused by the veins in the turbo sticking check the actuator for smooth operation it was sticking open
The last few we have seen have be caused by the egr solinoid
The solenoid in question is under the drivers seat bolted on the inner chassis section towards the back of the engine bay there is a few bolted together but it's the one that is vertical on the bracket

The last one we had with that fault turned out to be the actual egr valve even though it look to be working fine

We have spend a lot of time looking at this fault and each time it keeps us guessing

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