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p0402 fault on a 1.4 hdi. egr blanked off.
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arnoldrimmer

Posted: Sat Dec 10, 2016 11:22 am

Joined: Dec 02, 2016
Posts: 5
Trade Rating: 0
Location: newcastle

Ive aquired myself a 2005 1.4 hdi with 120000 miles on it. it came with the abs light on constant and abs not working.. I thought replace sensor, jobs a good un. Pulls Ok I think.. First time I drove one of these, coming from a 1.5 dci clio.

Using an el cheapo elm327 and torque to scan codes I received a solitary P0402 code..
nothing from the abs.

So with the info I had, and waiting for Diagbox to turn up. I removed the egr, which was reasonably clean.. cleaned it a little more and decided to stick in a blanking plate and a screw it the vacuum pipe.

no more egr valve i hope.

When doing this, I found the air filter was black.. like worst ive seen..
what I noticed was, the pipe attached to the egr valve. where it connects to the engine wasnt sealed correctly (no o-ring), so put an o-ring on it and now fits much more snuggly.

Im thinking exhaust gasses were leaking from here and the air filters sucking it back in..

Diagbox turned up, and give it a scan... whole load of errors including the P0402, others mostly related to the MAF. Cleaned the MAF, cleared the codes and been using the car pretty regular and only the P0402 code has returned. Thinking they might have replaced the MAF in the past but not cleared the codes.

Diagbox also told me the rear abs sensor is kaput. go pp2000!

P0402 Permanent fault. Air inlet circuit air flow higher than recommended

Now looking up the P0402 error. it says to check for a blown turbo.. I dont know how to check for a blown turbo.
what I can say is that it has a bit of whine noise to it. Cant hear it on normal drives or if someones in the car, but alone night driving I cant stop hearing it and thinking its gonna explode Very Happy

happened in a golf tdi a few years back and killed the car for me.

I took the pipe from the turbo off to wiggle the inside.. I think there is a miniscule bit of play, but very hard to detect, feels like finger tip fat could be hindering this test Very Happy

any ideas where to go next. Should i relook at the once leaky egr pipe seal to the engine.. Something with the turbo.. or investigate the vacuum system?
I still have to replace the abs sensor.

One last thing.. where is the location of an oil 'filter' sieve type thing to the turbo? I replaced the oil and filter and that was a bit manky too.. Just want to make sure its clear for piece of mind.

thanks.

arnoldrimmer

Posted: Mon Jan 02, 2017 6:17 pm

Joined: Dec 02, 2016
Posts: 5
Trade Rating: 0
Location: newcastle

for a bit of closure..
had a bit squirt around with wd40 looking for air leaks.. found me egr blanking plate had a possible tiny leak.. not really convinced...instant gasketed.

Im sure the manifold on the metal pipe to the egr valve was leaking still. its plastic had chipped away where they tried to force the pipe in. So stuck a second larger o ring, and went nuts with instant gasket.

a week or two later the codes still gone ..and still paranoid about the turbo Very Happy

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