PT Cruiser Diesel Headaches, help?!
Discussion
This seems to mundane against all your lovely big American cars but it seemed the best place to put this. It's long and I'll endeavour to explain as best as a mere girl translating from a bloke can lol.
04 PT Cruiser Diesel 2.2 CRD.
Been having problems with the engine management light (MIL)coming on intermittently for a number of miles, until more recently when it has appeared constantly. Now the light only goes off when the temperatures are very low. The car is outside so when we come to it in the morning, if its been especially cold the light won't appear until the engine warms up.
I took it in for diagnostics and they have identified a P0401 code - EGR Valve insufficient air flow. They have cleaned the valve, took for test drive and they say it ran fantastically, but, when back at the garage (i.e when it warmed up) the fault returned. The Garage tells us the EGR Valve is clean but the induction system/channels may be clogged and suggest basically that we rev the balls off it for a few miles to try and clear it.
The second problem is slightly more confusing. The car recently began to display a red air bag light. The garage have identified which air bag etc only it appears to be showing a fault in the passenger air bag curtain, something which mystifyingly isn't fitted in the car!
These 2 niggly problems are really starting to get us down. Does anyone have any advice or similar experiences here that we can draw on in a desperate attempt to try and solve the problems.
Thanks for reading!
Jane
04 PT Cruiser Diesel 2.2 CRD.
Been having problems with the engine management light (MIL)coming on intermittently for a number of miles, until more recently when it has appeared constantly. Now the light only goes off when the temperatures are very low. The car is outside so when we come to it in the morning, if its been especially cold the light won't appear until the engine warms up.
I took it in for diagnostics and they have identified a P0401 code - EGR Valve insufficient air flow. They have cleaned the valve, took for test drive and they say it ran fantastically, but, when back at the garage (i.e when it warmed up) the fault returned. The Garage tells us the EGR Valve is clean but the induction system/channels may be clogged and suggest basically that we rev the balls off it for a few miles to try and clear it.
The second problem is slightly more confusing. The car recently began to display a red air bag light. The garage have identified which air bag etc only it appears to be showing a fault in the passenger air bag curtain, something which mystifyingly isn't fitted in the car!
These 2 niggly problems are really starting to get us down. Does anyone have any advice or similar experiences here that we can draw on in a desperate attempt to try and solve the problems.
Thanks for reading!
Jane
They don't sell Diesel Cruisers here in the U.S. (and I'm a Ford petrol mechanic), but I think you would need to look at the sensor that controls the EGR valve. P0401 insufficient EGR flow detected usually points to the sensor controlling and not the EGR valve itself.
Ford's DPFE (delta feedback pressure of EGR) and older EVP (EGR valve position) sensors are notorious for going bad and that is the code that gets set when they do.
Hope this helps.
Ford's DPFE (delta feedback pressure of EGR) and older EVP (EGR valve position) sensors are notorious for going bad and that is the code that gets set when they do.
Hope this helps.
Edited by Trooper2 on Wednesday 19th January 05:34
2 interesting suggestions there, thanks Gents. First port of call I think is to try and get to the boost hose and see if there are any signs of a split. Failing that I think we'll go down the 'replace sensor' route.
I think also, just to rule it out we'll replace the air filter too, though I'd be surprised if it came down to that to be honest.
Thanks again gents, Ill let you know how we go on! Still looking for a solution on the airbag light though if anyone can help?
I think also, just to rule it out we'll replace the air filter too, though I'd be surprised if it came down to that to be honest.
Thanks again gents, Ill let you know how we go on! Still looking for a solution on the airbag light though if anyone can help?
Even if the Cruiser doesn't have side curtain air bags it most likely is wired for them and they will have a plastic cap in the connector to keep dust out, etc. The SRS system connectors have devices called "Shorting Bars" in them, so that when the connector is unplugged for diagnostic purposes a technician can't start setting off airbags with there DVOM meters.
The way the shorting bars are supposed to work is that when the connector is unplugged these bars make contact with each other to safe guard that airbag circuit and when the connectors are plugged in together the bars are separated so the circuit works normally. We just worked on a Crown Victoria Police cruiser that had an issue were it keep throwing a side curtain airbag code (also not fitted to this vehicle) and we tracked it down to the shorting bars in that deadheaded connector being in constant contact. Since your issue is intermittent it could also be something like a pinched wire, a bare wire sometimes shorting to ground, dirt or water got in that connector, etc.
The way the shorting bars are supposed to work is that when the connector is unplugged these bars make contact with each other to safe guard that airbag circuit and when the connectors are plugged in together the bars are separated so the circuit works normally. We just worked on a Crown Victoria Police cruiser that had an issue were it keep throwing a side curtain airbag code (also not fitted to this vehicle) and we tracked it down to the shorting bars in that deadheaded connector being in constant contact. Since your issue is intermittent it could also be something like a pinched wire, a bare wire sometimes shorting to ground, dirt or water got in that connector, etc.
Right, smallish update courtesy of my other half. We haven't looked any further into the airbag issue yet, mostly due to not being able to get the car into the garage and it being bloody cold outside. Anyway, other half tells me:
Can't see any pipes below egr valve but have traced airpipe towards back of engine - and found an electrical connector just out of reach but caked up with dirt so plan to clean it when weather warms slightly.
Some live data from code reader:-
P0401
Calculated Load 15.29%
Coolant Temperature 125.59F
Intake m.a.p. 2.93inHg
Engine Speed 833rpm
Vehicle Speed 0mph
Also very occasionally get a P0070 code which says Ambient/Outside air temperature sensor - circuit malfunction.
Can't see any pipes below egr valve but have traced airpipe towards back of engine - and found an electrical connector just out of reach but caked up with dirt so plan to clean it when weather warms slightly.
Some live data from code reader:-
P0401
Calculated Load 15.29%
Coolant Temperature 125.59F
Intake m.a.p. 2.93inHg
Engine Speed 833rpm
Vehicle Speed 0mph
Also very occasionally get a P0070 code which says Ambient/Outside air temperature sensor - circuit malfunction.
Hi that small boost pipe you will need to undo the grill and top panel above the rad should be 4 7mm head bolts for the grill then 4 10mm head bolts for the top panel then pull the rad and fans forward you will see the intake manifold and egr/air flow control valve assembly connected under that will be a 4 or so inch boost hose with your hand cause visibility is poor feel the hose they normally split round the back
The hose is marked with the red ring and sit's at the front of the engine.
This usally give's a different code to what you have but worth checking.
Loose connection's under the seat is also favorite for airbag light to come on.
Remember to take the key's out of the igintion and leave for ten minute's before checking the connector's.
This usally give's a different code to what you have but worth checking.
Loose connection's under the seat is also favorite for airbag light to come on.
Remember to take the key's out of the igintion and leave for ten minute's before checking the connector's.
Cheers Sprint, we had a problem with the core plug blowing spectacularly out before Christmas, emptying every last bit of coolant into the engine bay! He had to dismantle most of the front end to replace, while there that hose was replaced too so its not that one. Interesting to see the engine out of the car and not shoehorned into the bay though! You don't have a bigger version of that picture do you? It may help for future reference.
He's read on the internet that the problem could be due to faulty DPFE sensor so that's the next thing to investigate.
He's been in the garage most of the afternoon fiddling with the airbag wiring with no success annoyingly. Have tried all the suggestions here but we still have the light. I don't think I mentioned earlier but it did go to an auto electrician for the airbag last week who was also totally stumped. We do have a spare set of seats for the car (don't ask, my husband has a thing for seats, we have 6 seats for a TR6 as well.....) so the next line of thought is perhaps replace the whole passenger seat and see if that makes any difference.
Its been an incredibly frustrating couple of months really, we've had the car from new and she's covered over 100k now, just seems like this one has us completely stumped.
Really grateful for all your help here! I owe you all a beer
He's read on the internet that the problem could be due to faulty DPFE sensor so that's the next thing to investigate.
He's been in the garage most of the afternoon fiddling with the airbag wiring with no success annoyingly. Have tried all the suggestions here but we still have the light. I don't think I mentioned earlier but it did go to an auto electrician for the airbag last week who was also totally stumped. We do have a spare set of seats for the car (don't ask, my husband has a thing for seats, we have 6 seats for a TR6 as well.....) so the next line of thought is perhaps replace the whole passenger seat and see if that makes any difference.
Its been an incredibly frustrating couple of months really, we've had the car from new and she's covered over 100k now, just seems like this one has us completely stumped.
Really grateful for all your help here! I owe you all a beer
I have an update!
After reaching the end of the rope, it went in to Chrysler yesterday who diagnosed a faulty EGR Solenoid. Comically, our local Chrysler dealer, who are about a useful as a chocolate fire guard, couldn't find a part number for this solenoid so couldn't quote a part price.
On arriving home we made a quick call to Mercedes, established the part number, collected the part and fitted it. Chrysler called us ten minutes ago....they still can't find the part number lmao
So far so good (touch wood), no Engine Management light and the turbo appears to be functioning properly again. The solenoid is protected from road spray by a plastic cover within the wheel arch, a cover which needs to be removed to change the headlight bulbs. It would seem we no longer have that cover, and the fault first appeared after driving through a large puddle. It could be coincidence I guess but it seems likely the solenoid was soaked.
As for the air bag, Chrysler reckon the fault lies within the seat itself so I think we will replace both front seats now and see if that works. It was something that was planned for today but it's trying to snow here and far too cold to be messing around on the drive.
After reaching the end of the rope, it went in to Chrysler yesterday who diagnosed a faulty EGR Solenoid. Comically, our local Chrysler dealer, who are about a useful as a chocolate fire guard, couldn't find a part number for this solenoid so couldn't quote a part price.
On arriving home we made a quick call to Mercedes, established the part number, collected the part and fitted it. Chrysler called us ten minutes ago....they still can't find the part number lmao
So far so good (touch wood), no Engine Management light and the turbo appears to be functioning properly again. The solenoid is protected from road spray by a plastic cover within the wheel arch, a cover which needs to be removed to change the headlight bulbs. It would seem we no longer have that cover, and the fault first appeared after driving through a large puddle. It could be coincidence I guess but it seems likely the solenoid was soaked.
As for the air bag, Chrysler reckon the fault lies within the seat itself so I think we will replace both front seats now and see if that works. It was something that was planned for today but it's trying to snow here and far too cold to be messing around on the drive.
Well, spoke to soon.
Chrysler's diagnostic of a faulty solenoid was not accurate. We replaced the solenoid, took it out on Saturday and lo and behold, the light returned. Fortunately we managed to get a refund on the £90 part we didn't need....
In frustration we stripped the whole car down on Monday and found......the EGR Valve is knackered. Now awaiting an EGR Valve to be delivered. As for the air bag light, that issue is still ongoing and we have yet to swap the seats over.
Ben, our local dealer is Cumbo...
Chrysler's diagnostic of a faulty solenoid was not accurate. We replaced the solenoid, took it out on Saturday and lo and behold, the light returned. Fortunately we managed to get a refund on the £90 part we didn't need....
In frustration we stripped the whole car down on Monday and found......the EGR Valve is knackered. Now awaiting an EGR Valve to be delivered. As for the air bag light, that issue is still ongoing and we have yet to swap the seats over.
Ben, our local dealer is Cumbo...
I found the cause of the airbag light coming on, appears a common fault, there are a pair of wires that run up and under the seat ( the left hand one in my case ) these run to the air bag in the seat and due to the wires running over the frame if the seat the wire gets compressed and results in the wire being cut "INSIDE" the plastic covering and is not visable to see, I found it by gently pulling the wires and found one would stretch, You will have to be very careful as using a meter on the cables could cause the bag to go off, best to disconect the battery and the cable when safe 
As for the EGR , there are identical two valves, aka DIESEL TURBO PRESSURE REGULATOR
with air pipes going to various areas of the engine, one on the bulk head and one on the right of the engine bay (this on a diesel) they are the same and when playing up put the fault code on as the egr/waste gate valve, this could just be a split pipe or the valve or the DIESEL REGULATOR FILTER, these can be found on
ptcompany.co.uk
As for the EGR , there are identical two valves, aka DIESEL TURBO PRESSURE REGULATOR
with air pipes going to various areas of the engine, one on the bulk head and one on the right of the engine bay (this on a diesel) they are the same and when playing up put the fault code on as the egr/waste gate valve, this could just be a split pipe or the valve or the DIESEL REGULATOR FILTER, these can be found on
ptcompany.co.uk
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