Running problems and CEL - EGR related?

[bearfaced]

Hi all

I'm wondering if someone can help me with a problem I have with my 2.0 Diesel, it's been a long saga and I'm still in the dark.

A few months ago my Check Engine Light came on along with my traction control warning light (the car symbol with the tyre marks beneath it). I took it to my Mazda dealer as it was service time and they said that it might need a new EGR valve. They carried out a MAF relearn and reset the fault codes and all was well for a while.

A few weeks later the same warning lights illuminated - I took the car in for repair and the fault codes read:

P0001 - Fuel volume Regulator Control Circuit Open
P0401 - Exhaust Gas Recirculation Flow - Insufficient Detected

C3800 - None seems to know what this one is.

I had a new EGR valve fitted and all seemed well for a while - then I noticed at certain revs (approx 1250 RPM) the engine sounds a bit more noisy - more like a transit van. It also feels a bit lumpy with a slight vibration at that speed. The same warning codes came on - and the mechanic said that I should try adding some Forte fuel treatment and see if that helps. He reset the codes and added forte - all seemed well for a while.

To cut a long story short - this keeps happening and Mazda reckon the only way to find what's causing the problem is to replace parts (at my expense) until the fault goes away.

I have a few theories of my own but I've reached a dead-end at the moment.

Please... can anyone help?

Many thanks

Justin

[SJG2004_01]

Hi,

Did you ever get anywhere with this? I`ve got the exact same problem apart from mine is showing error codes:

C3F03
C3800
P0401

Changed the ERG valve at a cost of £400, Now Mazda are suggesting we change the DPFE sensor and do a ECU re-map working on a cost of around £500 tops.

Just wondering if you managed to get anywhere and possibly point me in the right direction. I have no problem spending the money, just don`t want to spend ever more just to be told by Mazda its something else etc.

Many Thanks
Best Regards
Si

QUOTE (ts2 @ Jun 3 2008, 12:19 PM)

Hi all

I'm wondering if someone can help me with a problem I have with my 2.0 Diesel, it's been a long saga and I'm still in the dark.

A few months ago my Check Engine Light came on along with my traction control warning light (the car symbol with the tyre marks beneath it). I took it to my Mazda dealer as it was service time and they said that it might need a new EGR valve. They carried out a MAF relearn and reset the fault codes and all was well for a while.

A few weeks later the same warning lights illuminated - I took the car in for repair and the fault codes read:

P0001 - Fuel volume Regulator Control Circuit Open
P0401 - Exhaust Gas Recirculation Flow - Insufficient Detected

C3800 - None seems to know what this one is.

I had a new EGR valve fitted and all seemed well for a while - then I noticed at certain revs (approx 1250 RPM) the engine sounds a bit more noisy - more like a transit van. It also feels a bit lumpy with a slight vibration at that speed. The same warning codes came on - and the mechanic said that I should try adding some Forte fuel treatment and see if that helps. He reset the codes and added forte - all seemed well for a while.

To cut a long story short - this keeps happening and Mazda reckon the only way to find what's causing the problem is to replace parts (at my expense) until the fault goes away.

I have a few theories of my own but I've reached a dead-end at the moment.

Please... can anyone help?

Many thanks

Justin[/b]

[grafixmaster]

I see this post has no answer yet.
I have the exact same problem with identical car
(CD engine, 2ltr turbo diesel 2006 registration in UK)

Error codes,
C3F03
C3801
P0401 - EGR flow insufficient detected.

Had the EGR valve replaced, the small vacume pipe to the valve and the sensor on top.

Car goes 35 miles before both lights come back on. skid light 1/2 sec before the MIL.
Same lumpy engine at 1250rpm.

Injector cleaners made no difference.

I can do most work any garage does, so any pointers in the right direction would be good.
I've had same suggestion from garage of a re-code of the ECU. all extra money.
I looked at the EGR valve when they took it off, covered in soot(inside) and internet searches show these mazda 6 ones have a known problem?!

Had other problems as well, but probably not related.
Alarm goes off on its own, random. once every couple of months or so.
Got locked in the car, had to climb out the window!
blows new bulbs too often. (don't put fingers on bulb glass, before anyone says so)
charging volts 14.3v so no probs there. Not put a scope across it yet to see if there are any high voltage peaks.

I've worked on cars for 20yrs
the lumpy revs at 1250 implies problem is not at the EGR unless there is a BIG hole somewhere, we would have seen that!?
E.g oil filler cap missing kind of size.

Keep the post alive.

Alan.

[grafixmaster]

I've managed to get hold of someone helpful in the Mazda service department.
They tell me the "C" codes mean nothing to them.

So where they are coming from is a mystery?
Someone in Mazda coded this ECU, they must know something somewhere...
Computers don't do "random"

I am told the fix for the EGR valve (without replacing) is to drill the vacuume hole wider in the valve.
Taking my car to the garage later today to see what they say.
My EGR has already been replaced with a new one, couple of months ago.
So I am not expecting this to be the problem still???

Keep you posted.

[Coromandel]

Same problem with 2.0 diesel

Warning lights for engine management and stability control. Variety of codes, Mazda technical not certain of cause, EGR looked promising, replaced at £350.

Codes cleared, lasted for 3 weeks before resuming.

Air bag warning appears now and then for some variety and usually clears on engine restart.

Mazda advise possibly ABS sensor, possibly control module, possibly....

Engine seems to run ok, currently cleared again by itself, think I will just run it and see how it goes rather than empty the bank replacing adhoc parts with no clear causation.

[joynul]

I've got the same problem - both engine check and traction control lights are permenantly on.

Does anyone here know where on the car the EGR or related items are fitted?I've got a feeling this is related to the frontal collision. But I fear bodyshop may say it is a coincidance and nothing to do with the front end collision.

I recently had a crash, with severe frontal damage. I've had the car returned by the insurance/bodyshop (Thu night). But as well as finding various issues with the quality of the repair (Sat morning) I also realised there was about 2.5 litres of coolant missing! After filling radiator with more water, I noticed the above warning lights had come on.

I'm in the middle of putting all the issues in writing to the garage and my insurance company, when I came across this webpage.

Appreciate any help or advice from anyone.


Thanks

[hybrid]

QUOTE (Joynul @ Nov 23 2009, 02:55 PM)

I've got the same problem - both engine check and traction control lights are permenantly on.

Does anyone here know where on the car the EGR or related items are fitted?I've got a feeling this is related to the frontal collision. But I fear bodyshop may say it is a coincidance and nothing to do with the front end collision.

I recently had a crash, with severe frontal damage. I've had the car returned by the insurance/bodyshop (Thu night). But as well as finding various issues with the quality of the repair (Sat morning) I also realised there was about 2.5 litres of coolant missing! After filling radiator with more water, I noticed the above warning lights had come on.

I'm in the middle of putting all the issues in writing to the garage and my insurance company, when I came across this webpage.

Appreciate any help or advice from anyone.


Thanks[/b]

I am not sure if this is a bit late, but the EGR valve is located at the front passenger side (right hand drive model) of the engine compartment. It is mounted on the engine block by two bolts. You can see its location on page 19 of the following http://www.scribd.com/doc/6905245/manual-diesel-Mazda-6.

Hope this helps!