IAT and EGR HPi Petrol Engine

[GTXJez]

Hi All
Been having issues with 'Anti Polution' Fault and EML on.

Had car diagnosed Codes are:
P1113 Intake Air Temp Sensor (Circuit Open/Short)
P0403 EGR Valve (Circuit Open/Short)

Advised that these is the probable cause, will also explain slight misfire?
Thoughts appreciated

Looks like I can get a IAT cheap enough on Ebay (£8-£15) not sure about EGR though, any advise cheapest I have seen is £171 + VAT and Delivery?

Where are these items on the engine

Also, my Engine is the HPi Version so rare? or are they the same on all 2.0 16v engines? or even all PSA Petrol lumps?
As I may be able to get a recon or one of a newer but different model.

If anyone has one in good nick, let me know.

Thansk in advance

[waue1978]

Best suggestion I can come up with is to use Servicebox & compare the part numbers between yours & a normal 2.0 petrol.

[GTXJez]

Hi All

RESULT - after supposed Error Codes for IAT Sensor and EGR Valve.

Turns out it is the pipe that goes from the throttle body, to the Cam Cover? (also spits to the Air Filter Box)
Had slpit right across at the point where it attaches to the camcover.

Probably explains why the IAT Error came up and the EGR Valve issues

Replaced EGR as a matter of course, fingers crossed it stays fixed

Keep you posted :-)

[GTXJez]

Well that didn't work either!
EGR replaced with a 2nd Hand One (probably knackered too) IAT Sensor and Breather Pipes that run from the top of the Cam Cover to the Air Intake (with a vacuum hose also)

Problem with a vengeance!

Towed to a garage in Tadley.

Ideas appreciated.............

[Welly]

The HPi is so rare here that there's a lot of head-scratching when it comes to faults

I've changed the thread title to provoke a bit more attention for you (hopefully).

[GTXJez]

Thanks 'Welly'
Yep plenty of head scratching even by the Dealers, watching thumping too (I hope not )

Seems like it may be a fuel pressure regulator which would explain the starting then stopping, plus being intermittent, and the possible connection to the air breather pipes - not as wallet whacking as a new Fuel Pump, but had a new one fitted at 85,000 only on 107k now?

Fingers still crossed

[GTXJez]

Hi All

Its get's worse

After trying a replacement EGR valve, Engine Breather Pipes and still had the same cutting out problem!
It died the other night and refused to restart, I got the car into a local garage after the men in Yellow rescued me.

The AA diagnosed a faulty EGR and IAT Sensor, both were done, car seemed fine for a few days.
But the dreaded 'Anti Pollution Fault' came back along with the Engine management light.

The garage diagnosed a 'fuel pressure regulator' which was changed at a cost of over £310, but the car is now worse!

1. It wont idle and runs away at 2,500 rpm
2. The exhaust glows red hot!
3. Strong burning smell (electrical?)
4. White smoke for the exhaust!
5. The brake servo is not working!
6. The radiator cooling fan runs on for 15 mins after the car is turned off!!

Certainly wasn't like that before it went in
They have diagnosed a faulty ECU - any thoughts

I can't see that the ECU would have gone and caused all these issues maybe it has or was damaged by the garage.....

The previous owner replaced the Valve Solenoid, High Pressure Fuel Pump, various sensors, oxygen senor (lambda) I have given it a full service?

Hoping and praying that the ECU hasn't gone at £730 + VAT the car is a right off.

I would appreciate any advice on where to start looking?

HELP!!!!

[lozz]

Loom fault pehaps,
ive just replied to your other thread,

[GTXJez]

cheers lozz

[highlander]

Note - I'm not very technical, car-wise, so I'll call these as I see them based on my own limited experience:

1. It wont idle and runs away at 2,500 rpm

Could be the air intake. My 2.2 petrol had a problem with a gasket that sits between the throttle body and the air inlet manifold. The gasket had perished and crumbled away, which affected the air flow to the engine. Once the gasket was replaced, this problem disappeared.

At the time, I was also advised it could be the sensor that taps into the pipe between the airbox and the throttle body - check that this sensor is functioning and replace if necessary.

2. The exhaust glows red hot!

A sure sign of over-fuelling - unburnt fuel is exiting through the exhaust manifold and into the exhaust pipe, where it is igniting on contact with the hot exhaust pipe. There's nothing else that I could possibly think of that could cause the exhaust to glow red hot.

This issue may be as a result of extra air getting in to the engine (see my answer to your idling problem) but could equally be caused by a faulty ECU, unfortunately.

This is one specific issue you'll want to get sorted, and FAST. Not only is this undoubtedly causing a lot of damage to your catalytic converter, if the exhaust is hot enough you could end up with a fire on your hands.

3. Strong burning smell (electrical?)

May be the exhaust and/or the contents of the cat, due to the over-fuelling issue.

4. White smoke for the exhaust!

Again, I'm sticking with the over-fuelling issue.

5. The brake servo is not working!

I don't know enough to comment on this one - possibly heat-related?

6. The radiator cooling fan runs on for 15 mins after the car is turned off!!

If there is an over-fuelling issue, you'll find that the whole engine block and the engine bay surrounding it becomes much hotter than it should do, therefore requiring more time to cool down after the engine has been switched off. The fans are electronically controlled and are on a permanent live (which is why you need to disconnect the battery before working on the fans because they can be switched on and off without the key being in the ignition). Again, this could be related to a faulty ECU.

I'm hoping that what you've got is one single under-lying fault that is causing all these symptoms. To my untrained eye, it looks like it - but you'll need someone more knowledgeable than me to pinpoint the source.

Hope this helps in some way.

[lozz]

Anyone seen the list of 406 Recalls?

......................................................................................................................................................
Recall: No. 3 of 15
Recall Ref: R2001/093
Exact Model: 406
Description: BRAKE SERVO VACUUM PIPE
VIN:
Build Date:
Numbers: 195
Defect: Brake servo vacuum pipe may become damaged due to chafing on engine wiring harness. This could result in a loss of braking assistance
Action: Recall affected vehicles, replace and reposition the servo vacuum pipe to avoid further chafing.
Launch Date: 03 August 2001
.................................................................................................................................................

Recall: No. 1 of 15
Recall Ref: R2000/004
Exact Model: 106 206 306 406 and Partner
Description: POSSIBILITY OF LOSS OF BRAKE SERVO ASSISTANCE
VIN: TO BE ADVISED
Build Date: To be advised
Numbers: 18405
Defect: There is a possibility that the brake servo valve may not function properly, resulting in loss of servo assistance to the braking system.
Action: Recall affected vehicles for the inspection and possible replacement of the brake servo valve.
Launch Date: 01 February 2000
.........................................................................................................................................................

[lozz]

Recall: No. 5 of 15
Recall Ref: R/2009/022
Exact Model: 406 EW10D HPI
Description: FUEL MAY LEAK
VIN:
Build Date: .
Numbers: 14
Defect: It has been identified that a batch of high pressure fuel injection pumps supplied as spare parts may not have been manufactured to specification. As a result a fuel leak may occur.
Action: Recalled vehicles will have the subject fuel injection pumps changed.
Launch Date: 13 March 2009

[lozz]

this one sounds about right,

Recall: No. 9 of 15
Recall Ref: R2001/012
Exact Model:
Description: REAR SUSPENSION FIXING BOLTS
VIN: BUILT OUT OF VIN SEQUENCE
Build Date:
Numbers: 3372
Defect: Incorrect specification rear suspension arm pivot fixing bolts could fail under arduous operating conditions, possibly resulting in the rear wheel locking.
Action: Recall potentially affected vehicles, examine the pivot fixing bolts and renew with ones of correct specification where necessary.
Launch Date: 19 January 2001

[GTXJez]

Hi Chaps
Once again fantastic response, thank you very much!
Hihglander excellent breakdown, and lozz with the recalls you guys are amazing!

All logical, and from what you guys have said and after what I have seen on other sites, excessive air intake to the inlet manifold (or throttle body/MAF) would not only cause the engine to run faster and cause additional fuel to be drawn in, therefore excess fule could be being burnt in the exhaust? (white smoke, burning smell etc...)
It would also explain why the brake servo's not working as it also connected to the inlet manifold? and they had to take off the Inlet Manifold and all pipes to get at the 'fuel pressure regulator' ummmmmmmmm.............

I had NONE of these issues at all BEFORE it went into the garage, although I had the starting and cutting out problems (intermittent) when it did run it was super smooth
I do suspect that the fuel pressure regulator was faulty (backed up by one of the three AA reports) indicating fluctuations in fuel pressure from 65 -80 bar when normal should be about 125 bar (from what I have been told!) and also possibly a faulty EGR and IAT Sensor that may have been problematic too.

I seriously believe that he fundermantal mechanics of my car are excellent, just these associated problems of late.
Oil Temp never high, no oil or water loss, water temp always spot on 90 and never moves, starts evry time, excellent MPG, gearbox, clutch brakes and all other components are almost as new, no other electrical faults ?
After 20,000 miles of trouble free reliable motoring, you do get to know your own car!

I hasd similar experience a few years back when I had a Hyundai V6 Sport (200bhp and bullet proof reliability ) had a faulty clutch change at Mr. Clutch, within weeks the gearbox dumped its Oil and the gearbox seized £1,800 later (not including the clutch at £700) it was diagnosed as faulty workmanship as certain pipes had not bee reconnected properly, I went through the courts for compensation, but all I got was a £500 Voucher/Credit Note, needless to say I didn't go back to them again

I will througky check all the inlet manifold pipes first and then get a reliable garage to check it out, my only hope is that the ECU hasn't been damaged in the process, otherwise I am looking at a write off, which would be a shame as the rest of the car is spot on?

Once again many thanks guys sure we may well comment soon, if not have a Great Xmas and New Year!!!

[GTXJez]

Hi All

Firstly thanks for all the advice - spot on! and you were 90% right too

Eventually diagnosed as not only a faulty EGR and IAT Sensor but a Fuel Regulator, which was replaced £135 + VAT Peugeot Only)

BUT the problems that I was left with (Red Hot Exhaust, High Idle etc...) was down to a pipe clip that was broken on re-assembly and not replaced - £10 for Peugeot.
WAs on the short the Metalised Pipe that goes from the EGR to the Inlet Manifold, simple but very expensive mistake by the garage (for me £210) so I will be going back to the 'other' garage for a rebate!

Fingers Crossed the problem is sorted, time wil tell certainly better than before I had these problems!

Moral of teh story is, use a decent garage who knows what they are doing qand are 100% honest!! and or get the problem diagnosed correctly (sure we all know that anyway)
Thanks for all your help.

Have a Great Christmas and New Year