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Vauxhall Zafira 2.0 Y20DTH 2004 - EGR fault, code P0400 #

Posted by Ian Durston on March 26, 2016, 4:44 pm

Year of Manufacture *: Zafira registered 2004
Engine Size and Code *: 2.0 diesel y20 dth
( Optional ) Scanner Used: Various
( Optional) Fault Codes: P0400

P0400 fault code-feedback signal incorrect.4 wire sensor. Power and ground good. I can command valve open, duty cycle changes and valve opens, but feedback duty cycle stays the same, have plugged in new whaler egr and feedback is the same as old unit. I expected to see a change in feedback signal as the valve opens.i suspect faulty part but what are the chances of two valves having the same internal fault.one other possibility I am thinking is wrong part supplied, even though it looks perfect.please help

Re: Vauxhall zafira-egr fault code

Posted by Francis Bennett <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3809' width='330' height='300' border=0 style='border:none;'> on March 26, 2016, 4:57 pm, in reply to "Vauxhall zafira-egr fault code"
Francis Bennett

Hi may i just ask which diagnostic tool you are useing? ino the kts has a reset parameters function if so have you tried to do that? also have you tried scopeing the signal from the egr yourself?

Re: Vauxhall zafira-egr fault code

Posted by andy pethig <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3731' width='330' height='300' border=0 style='border:none;'> on March 27, 2016, 9:17 am, in reply to "Re: Vauxhall zafira-egr fault code"

i was thinking the same thing as francis, if you haven't you would want to check the feed back signal at the egr valve , and then again at the PCM if the signal looks good at the EGR.

Also you may need to carry out a base setting adaptation for the new part.

so i would clear the code , then adapt the new part in , then see if the code comes back,

then start testing.

Re: Vauxhall zafira-egr fault code

Posted by Ian durston <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3941' width='330' height='300' border=0 style='border:none;'> on March 27, 2016, 9:29 pm, in reply to "Re: Vauxhall zafira-egr fault code"
Ian Durston

Thanks for the response, no adaption option on the kts.the scope trace on the feedback signal at the valve is like a duty cycle trace 4.5 volt peak voltage, switching to ground.the trace looks good, but when I actuate the valve the frequency of the feedback trace does not change.any more ideas

Re: Vauxhall zafira-egr fault code

Posted by andy pethig <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3731' width='330' height='300' border=0 style='border:none;'> on March 27, 2016, 9:37 pm, in reply to "Vauxhall zafira-egr fault code"

if you are confident in what you are doing and are scoping the right wires, and your power and grounds check out, what else is there ??

where did you get the part from ?

ECP ??

Re: Vauxhall zafira-egr fault code

Posted by Ian durston <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3941' width='330' height='300' border=0 style='border:none;'> on March 27, 2016, 9:58 pm, in reply to "Re: Vauxhall zafira-egr fault code"
Ian Durston

Thanks for the reply, got the part from local factor mill auto quip .genuine walher part.i want to be 100 % sure 4.5 volts is correct.i have never seen a 4 wire egr like this before.i don't know how the brains in the egr valve produces the wave form I am seeing.

Re: Vauxhall zafira-egr fault code

Posted by andy pethig <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3731' width='330' height='300' border=0 style='border:none;'> on March 27, 2016, 10:25 pm, in reply to "Re: Vauxhall zafira-egr fault code"
Andrew Pethig

do you have auto data, you could look at the pin out info for the PCM it might give you the data you want.

Re: Vauxhall zafira-egr fault code

Posted by Job Gevers <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5524' width='330' height='300' border=0 style='border:none;'> on March 28, 2016, 7:47 am, in reply to "Vauxhall zafira-egr fault code"
Job Gevers

P0400 fault code is normally a general code which can be caused by various faults.

I would normally check air mass first, vacuum pump, vacuum lines and solenoids next.

Re: Vauxhall zafira-egr fault code

Posted by Ian durston <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3941' width='330' height='300' border=0 style='border:none;'> on March 28, 2016, 9:10 am, in reply to "Re: Vauxhall zafira-egr fault code"
Ian Durston

Thanks for the replies, I did look at all data over the weekend with no luck, I will see if I can use auto data this week.thanks for the idea.

Re: Vauxhall zafira-egr fault code

Posted by Peter Warman <iframe src='https://members.boardhost.com/ukautotalk8/info/user=Peter+Warman' width='330' height='300' border=0 style='border:none;'> on March 28, 2016, 12:11 pm, in reply to "Re: Vauxhall zafira-egr fault code"
Peter Warman

This is from UKAT Workshop Data

95 is the Glow Plug Relay
307 EGR Valve

HTH

Re: Vauxhall zafira-egr fault code

Posted by Ian durston <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3941' width='330' height='300' border=0 style='border:none;'> on March 28, 2016, 4:17 pm, in reply to "Re: Vauxhall zafira-egr fault code"
Ian Durston

Thanks Peter for the image, do you have pin out data for terminal 4.

Re: Vauxhall zafira-egr fault code

Posted by andy pethig <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3731' width='330' height='300' border=0 style='border:none;'> on March 28, 2016, 9:03 pm, in reply to "Re: Vauxhall zafira-egr fault code"

having looked at peters diagram the egr valve you have , has a permanent power and ground and the computer controls the transistor in the egr which controls the solenoid / pintle.

there is no position sensor in the valve, so not the typical feed back signal we would normally see when the valve opens.

check that the PCM can see the square wave at the computer on pin A19

feed back, EGR FLOW may be calculated by the air flow meter/ map sensor, or some other means

Wiring diagram symbols are not my strongest point, so this post may be a load of rubbish .

i wait too be corrected by some one with more knowledge than me.

Re: Vauxhall zafira-egr fault code

Posted by Francis Bennett <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3809' width='330' height='300' border=0 style='border:none;'> on March 29, 2016, 2:58 pm, in reply to "Vauxhall zafira-egr fault code"
Francis Bennett

hi again ian back in work today so i have had a look on my kts. two questions is your system edc 15m or psg 16 pump control? second if it is the psg which i think you have 1= pwm signal 2 = ignition live 3= earth and 4 is a shield wire. this is a cloosed loop circuit so it will get postion feed back from air mass lambda sensor map sensor so on so forth. if it is the other system though there is a adaptation reset.

Re: Vauxhall zafira-egr fault code

Posted by Ian durston <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3941' width='330' height='300' border=0 style='border:none;'> on March 30, 2016, 7:56 am, in reply to "Re: Vauxhall zafira-egr fault code"
Ian Durston

Thanks again for your feedback guys. To Francis it is psg6,where did you see on kts that pin 4 is a shield.thanks again

Re: Vauxhall zafira-egr fault code

Posted by Francis Bennett <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3809' width='330' height='300' border=0 style='border:none;'> on March 30, 2016, 8:05 am, in reply to "Re: Vauxhall zafira-egr fault code"
Francis Bennett

what package do you have for kts? it gives you a full test procedure for the egr. if pin 4 had importance ie was for sensor feed back it would give you a procedure to test that looking at, also there is no symbol on the egr that states it has one. you only have the transistor, mechanical component and coil symbols . I would try looking for a air leak, blockage or as was said the air mass.If you would like i will message the full test procedure over.

Re: Vauxhall zafira-egr fault code

Posted by Chris Angus <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat5111' width='330' height='300' border=0 style='border:none;'> on March 30, 2016, 12:25 pm, in reply to "Re: Vauxhall zafira-egr fault code"

Little bit of info for you Ian.

Pin one is activation of egr from ecu 12v dc

Pin two is supply

Pin three is earth

Pin four I'm not sure about, it is the 4.5 signal DC you have seen, but it doesn't seem to change when activated, didn't have enough time to do any other tests, but I'm thinking it's feedback, maybe current sensing?.

Some live data

Engine at idle
Egr command at 100% (off)
egr pulse ratio 95%
egr feedback ok
Maf 490 mg/stroke

Engine at idle
egr command 37%
egr pulse ratio 34%
egr feedback ok
Maf 280 mg/stroke

Engine at 1500rpm
Egr command 26%
egr pulse ratio 28%
maf 300 mg/stroke
egr feedback ok

Hope this helps

Re: Vauxhall zafira-egr fault code

Posted by ian durston <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3941' width='330' height='300' border=0 style='border:none;'> on March 30, 2016, 3:01 pm, in reply to "Re: Vauxhall zafira-egr fault code"

thanks again for all of your help.I am using kts 540 with esi, please show me what you are seeing.In response to Chris's information, this is what I am seeing on my zafira-4.5 volts on pin 4, static voltage doesn't change with erg position, when I scoped this signal(feedback) I am seeing a duty cycle with no change in frequency when I am actuating the egr valve diagnostically.On live data I am seeing the same pids as you but, egr feedback shows incorrect using auto diagnose & g scan 2, but egr feedback ok when using bosch kts.....help

Re: Vauxhall zafira-egr fault code

Posted by Chris Angus <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat5111' width='330' height='300' border=0 style='border:none;'> on March 30, 2016, 3:53 pm, in reply to "Re: Vauxhall zafira-egr fault code"

Just found a TSB for this fault.

Opel/Vauxhall Field Remedy: 1789

Models: Astra/Zafira etc.... Vectra-C 2002...2004, Signum 2002...2004

Subject: Engine Y20DTH/Y22DTR - Electrical EGR valve malfunction, DTC P400(C) and/or P0400(9) is set.

Complaint: EGR valve malfunction. Vehicle in emergency mode (with the above codes).

Cause: EGR position recognised but not valid in ECU. DTC will be set due to plausibility check? EGR feedback is NOT required by ECU.

Remedy: (note: for Astra-G and Zafira the EGR valve has to be dismantled).

Cut cable GYBK 0,5 (grey/black) from EGR valve pin 4 to terminal 19 at ECU plug directly at EGR plug (not at pump side.

See Dealer or TIS for details and diagrams.

There is also mention of a software update, it just depends when the fault code is set, when starting up (fix as above) or when driving (software update)??
If you were to use tech 2 it always gives the fault code and a subcode

I take it you've done a good smoke test on this?

Re: Vauxhall zafira-egr fault code

Posted by Ian durston <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3941' width='330' height='300' border=0 style='border:none;'> on March 30, 2016, 9:07 pm, in reply to "Re: Vauxhall zafira-egr fault code"
Ian Durston

Thanks again, The p0400 fault code occurs intermittently whilst driving & it has occurred a few times when just revving up in workshop. I have read about cutting feedback wire, but thought is was bull.i am waiting for customer to bring vehicle back to me to spend a little move time on it.Check to see what software version, etc.my tech 2 does'nt go back to 2004 so unable to see sub code.no No smoke test yet, I was really thrown with fault code relating to feedback, live data showing feedback incorrect on 2 scan tools & voltage on pin 4 being 4.5 volts without changing.going on diesel Bosch course in 2 weeks will be interested in hearing what mark Carter says about this feedback signal & what it means. Many thanks.

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