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220 Cdi gone into limp mode

TONTO

New Member
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Dec 31, 2009
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6
Hello everyone, this is my first post, and as with most new posts, it has been instigated by a desire for urgent info.
I recently purchased an 04 V2.2 Cdi 150 hp model with 80k on the clock and it was supplied by an independent.
The first day I collected the vehicle and was happily driving home the yellow engine symbol flashed up on the dash and the power dropped to around 30% ( this I now know as 'Limp Mode') I stoped, turned off the engine, turned it on again and it was fine, only for it happen again 5 mins later. I took the vehicle back to the dealer and he said he would have a look at it. A few days later it was ready for collection. The D said it was a clogged up waste gate on the turbo, it's been cleaned and it's all ok.
Driving home again, same thing happens, I take back to the D again, this time D changes the Turbo for a new one!!...
Since then I've had 1500 trouble free miles, that was until this weekend.
I was on a 150 mile run when shortly after filling the screen wash bottle (for the first time) the yellow engine light came on and Limp mode cut in, the main difference this time form the previous times was, turning the engine off and on again did not clear the yellow light or dissarm the Limp mode.
I took it to the main Merc dealer the next day and they told me a fault code showed the EGR valve needed to be replaced, and promptly gave me a quote of £490 to replace it. I called Motorplan, the warranty Co. provided by the dealer. They told me EGR valves are not covered which left me the problem of financing the repair.
After trawling through various MB forums it appears a very common theme seems to keep cropping up and that is stories of people spending large somes of money on MB dealership misdiagnoses which has led me to question my 'broken' EGR valve.
I have checked that all the rubber air tubes connecting the EGR with various other bits and pieces and are all clear and 'kink' , 'split' free.
I've sucked the tube connecting to the EGR and this lifts an arm connecting to the back of the turbo, additionally it holds the arm in the elevated postion when you clamp the tube, ruling out any small leaks etc.
On further investigation I noticed some small loose rubber hoses, one coming from a small motor on the side of the screen wash bottle and another tube, which had been cut which led to a disabled headlight washing system. The small length of pipe connected to the scren wash bottle was around 250mm long and seem to exit directly onto to EGR valve solenoid just behind the nearside headlight. When I filled the bottle up it then proceeded to empty 50% of it's contents over the solenoid.
I'm just putting two and two together here, this fault only occured after the bottle was filled up and the water leaking out of the tube was squirting directly on to the solenoid. I've taken out the solenoid and cleaned it, dried it but the yellow light will not clear nor the Limp mode.
Any possible insight, suggestions, similar experiences (unlikely) would would truley be appreciated.
Thanks Guys
 
I'll try, but I'm not very good at these things, I always get ' the file is too big' etc.:confused:
 
To me it sounds like your turbo was on its way out anyway and probably the wastegate was a bit sticky too and where the oil had been passing the charge air hoses it has clogged all the sensors on is way too. MB probably didnt clean the hoses out. Ad for the washer conected to the solenoid thats not right at all.
 
Sometimes disconecting the battery and attempting to turn the engine over removes any potential stored voltage from the system and resets the ecu worth a go !!
 
Ok this is my first attempt at posting a picture..

tonyoverington
 
Ok second attempt.. this is as big as I can get it.

The first image is obviously the engine layout.
IMAG00502-1.jpg



IMAG00591.jpg


Ok!! thats better... the picture above is the Turbo with the EGR to the rear with the tube and the actuator arm just protruding at the back.

IMAG00581.jpg


The picture above is the EGR solinoid which the screen wash water was pouring onto.
If this was faulty would it give an error code saying the EGR valve needs replacing?

I've got the hang of this picture posting now, so if any more pictures are required let me know.

The last one shows the cut off pipe coming from the water bottle (grey)
you can also see the end of the pipe that was originally connected in the top left hand corner.

IMAG00531.jpg
 
Hi ya, its hard to tell clearly from the picci but the round thing attatched to the turbo is the watse gate actuator and not the egr valve. Water on any electrical item will cause it to fail eventually so thid could be the answer but now im going to say something that may seem totaly random but the item you call the egr solenoid isnt one of the turbo boost sensors and one of the hoses you have found isnt meant to be connected to this is it??just wondering because anything on the turbo side can cause it to go straight into limp mode when faulty. Just a thought, please dont burn me alive im just trying to help

Cheers Martin

P.S just had another thought, check that the air pipes for the headlight adjusters are both connected as this can also bring on limp mode.
 
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My car is a 2000 model V220 Cdi My EGR is om the right hand side of your merc cover in the middle. Mine has a different looking layout but maybe you will find your EGR. Mine is an aluminium dome shape cover. Have it of now will try to post a pic soon. It was full with dirty crap, maybe your sensor is gummed up ??? But you will have to rule it out. It' seems maybe your turbo was buggered and now it's your egr .
 
OK.. PROBLEM SOLVED. Many thanks to those of you who have contributed, or should I say enlightend me in respect of identifing an EGR valve correctly. The truth is I was looking on the internet to get some idea of what an egr valve was and there were a few dud pictures which put me right off the track, anyway I got the local MB dealer to email me a diagram and with the help of you guys I managed to find the egr, whip it out clean all the crud off re-fit and HEY-PRESTO all working fine.. at last, going like stink.
I really thought this was going to be a van from hell after the initial problems, I'm generally quite pleased with the vehicle although it's suprisingly rusty for an 04 plate with 80K and the interior build quality is not what I expected considering it's a Merc. I owned an 02 Audi A4 for 6 years and I would definately say that was better.
Oh well I've just got to sort out why the fans are not working above the side doors in the rear.. I'll start with the fuse box.....
Thanks again guys.. oh and happy new year.
 
Well done Tonto. You are never aLone with the Rangers on here.

:doh:Coat already on.

Welcome to the Forum. £490 up and only five posts. That would make any ones New Year a Happy One:thumb:
 
I guess, when you turn the ignition on, a series of automatic checks are carried out prior to the vehicle being ready to start, and the egr, because it was stuck in the shut position, sent a fault signal to the ECU triggering limp mode. As soon as I cleaned the gunk off the valve it could move freely, therefore sending an 'all clear' signal to the ecu. I hav'nt got a clue why your's can't register it's dissconnected.

Trapperjohn: good point, well presented.. cheers mate
 
IMAG00591.jpg


Ok!! thats better... the picture above is the Turbo with the EGR to the rear with the tube and the actuator arm just protruding at the back.

I'm wondering if you can assist me with a question about this EGR valve. I've got a 2004 111CDI and I've located what you've identified in the picture on my vehicle. But all of the photos I am able to locate show something much different. See this page:
Mercedes C, E, S, Viano, Vito EGR Valve

Mercedes EPCNet lists the part number for the EGR valve as A6461400860 and shows a diagram that is similar to the part at the link above.

So which one is correct? I cannot find the second one anywhere on my vehicle so I am inclined to believe the one shown in your photo is correct. If that is the case, do you happen to know a part number for it?

Andy
 
Someone said already but that is the wastegate actuator not the EGR, which is probably why it looks different. Phone mb dealer they will tell you the correct part number for you vehicle
 

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