Citroen C5 Engine Problems

[st56]

Citroen c5 2003 2.0 hdi always run fine.Up until last week, started engine and engine management light came on and stayed on.The car wouldnt rev past 2800 rpm was driving home engine cut out and wouldnt start again, i then waited 10-15 mins car started drove at 2800 revs,also broke down once more after this on way home same thing happened again. Took it to a friends garage and put on diagnostic, 

 

Here is the list of faults :-

 

 

 

CODE PO246 TURBO PRESSURE MEASURED TOO LOW

 

CODE P1537 ACCLERATOR POSITION SIGNAL, ACCELERATOR PEDAL JAMMED

 

CODE PO380 ADDITIONAL HEATING CIRCUIT SHORT CIRCUIT TO EARTH OR OPEN CIRCUIT

 

CODE 1112 FUEL PRESSURE INFORMATION DETECTION OF HIGH PRESSURE LEAK

 

CODE P0100 MASS AIRFLOW SENSOR SHORT CIRCUIT TO BATTERY POSITIVE

 

CODE P1138 FUEL PRESSURE SENSOR INCORRECT

 

CODE P0235 TURBO PRESSURE SIGNAL SHORT CIRCUIT TO POSITIVE OR VALUE TOO HIGH

 

I will also add this garage cleared codes car was running fine and revving up no problem, drove it 3 mile home after this and car cut out again just outside my home and engine management light came on got it started again after 10 mins and drove it in my drive.Then switched it off took key out of ignition engine stopped 2 second after key was out of ignition lock. Don't think all these faults are right, i think the fault itself is causing all these codes with a knock on effect?

 

If anyone could help would be much appreciated please and thanks in advance

 

Regards John

[Randombloke]

So many faults - check the battery condition, yes, I know it starts, but what is the voltage when the engine is off and when it's running.

 

Check looms joints and connections to things like the BSI, BUT only do this after following the correct battery disconnect procedure, and then perform a BSI reset.

 

Otherwise, post a rough location and members will advise of a good Citroen independent.

[qman3428]

When was the fuel filter last changed? should be every 30k minimum, I need to do it every 20k because I use supermarket fuel. This is particular to the two fuel faults as it would cause them, the others I agree are sympathetic fauls caused by the main fault, also try a BSI reset.

[coastline taxis]

Get the car plugged back in and see what codes you have now.

[st56]

Ill definetely check the wiring, and change fuel filter and then get put on a machine again.Sorry for the late reply been hectic just now.Thanks for all the help and replys really appreciated. I will let you all know how i get on 

 

Regards John

[Motomech2905]

Hi I have a 2002 c5 2.2hdi 4hx engin fault code p0235 boost pressure sensor signal to high. Replaced intercooler was leaking cleared code stays out driving round town but as soon as get to bit of speed on slight hill the management light comes on and abs/esp light come on car doesn't lose power or anything and fault code is back

[paul.h]

Welcome to the forum.

 

Possibilities may be a faulty pressure sensor or a problem with the turbo wastegate or pressure regulation solenoid valve. To check will need a diagnostic check using a pressure gauge connected in with the pressure sensor to see if it is reading correctly and also using a vacuum pump with a pressure gauge to see if the wastegate actuator arm moves (should be 12mm +/- 2mm with 0.8 bar applied to the actuator).

 

A common problem to check is if the swirl valve actuator plastic ball joint has broken - this can be found at the gearbox end of the cylinder head. A new diaphragm actuator is only about £20 but is a pain to fit, but in reality only the plastic bit needs to be swapped over.

[hannah_gleeson]

Hi I have a 2002 c5 2.2hdi 4hx engin fault code p0235 boost pressure sensor signal to high. Replaced intercooler was leaking cleared code stays out driving round town but as soon as get to bit of speed on slight hill the management light comes on and abs/esp light come on car doesn't lose power or anything and fault code is back

regarding this code, after spending over £2000, i have found the problem, the wiring from the engine to the ecu becomes brittle and shorts out, if you replace the wiring, that should fix your problem, 

[hannah_gleeson]

 

Hi I have a 2002 c5 2.2hdi 4hx engin fault code p0235 boost pressure sensor signal to high. Replaced intercooler was leaking cleared code stays out driving round town but as soon as get to bit of speed on slight hill the management light comes on and abs/esp light come on car doesn't lose power or anything and fault code is back

regarding this code, after spending over £2000, i have found the problem, the wiring from the engine to the ecu becomes brittle and shorts out, if you replace the wiring, that should fix your problem, 

 

i must add the reason for the cost of £2000, my c5 had the following parts, 

new engine,

ecu tested, 

new turbo,

new intercooler,

complete new sensors,

complete new pipes,

new partifcate filter, and lasty was the wiring, which solved my problem, 

please note i am a mechanic by trade so £2000 to me would be about £3750 retail. 

[paul.h]

Welcome to the forum and thankyou for your posts, they may be of help in this current topic http://www.citroen-owners-club.co.uk/citroen/topic/21661-dreaded-espasr-anti-polution-fault/

[tampenny]

 

 

 

Where would I start looking for this wiring please ??

 

[paul.h]

tampenny, do you have the engine management light on and if so what are the fault codes or what problem do you have ? For this fault also all the sensor connecting hoses should be checked for any leaks/splits at the ends which can reduce the vacuum and result in the apparent faults of the turbo and other problems.

 

hannah_gleeson has not been on the forum since 4th August 2014 so we may not get an answer from this member.

[tampenny]

Hi Paul,

car has the following faults displayed on the display, 

Depollution system fault and occasionally ESP/ASR system faulty,

plus service light on dash,

 

took it to Citroen specialists who ran the diagnostics tool and discovered,

TURBO PRESSURE TOO HIGH, (torque regulation ??)

said this would account for the Depolution system fault and ESP/ASR system faulty,

also a sensor going to the fuel cap which tells it how much Eolys fluid to add is faulty,

 

they did a Mitevac test,

replaced all 3 main electro valves and re checked parameters, readings ok but same fault appeared on road test,

replaced Mass Air flow sensor and boost pressure sensor, still came up with fault,

recommend main dealer brake out box diagnostics,

 

would be lovely to think it is just a damaged wire !!!!

[paul.h]

From your other posts I believe you have a 2004 auto diesel, so I guess this will be a facelift C5 (2004 to 2008) with the 2.2 hdi 136 bhp engine.

 

The Mityvac test I suspect may have been a vacuum test for leaks on the sensor hoses or possibly to get the sensors to work and maybe check the turbo waste gate/variable vanes work. However, from things I have read, it may be possible the problems are caused by a split in the vacuum hoses to any of the sensors so you could check each hose and the hose ends on the sensors for any splits - just in case this was missed by the specialist.

 

The first faults noted can be caused on the 2.2 hdi 136 bhp engine by a plastic joint that fails near the gearbox end of the cylinder head on the swirl flap actuator or possibly its diaphragm failing - these are a common problem so your specialist should have noticed this. The actuator with the plastic joint is only about £20 but you can see if it works when the engine is switched on since the arm will move.

 

The wiring referred to is likely to be between the engine and the ecu/fusebox area so you could have a good look at all this for any damage.

 

Check that your fuel cap has 2 magnets in it which tell the car fuel is added when it is replaced after filling up so it knows to add the eolys fluid to the fuel tank.

[coastline taxis]

the esp fault and service light will disappear once you get the fault fixed so forget about them. your car needs to regenerate the dpf filter but cant because of the faulty sensor from the fuel cap. have you get the right filler cap on remember it needs to have reed magnets in it. any auto electrician should be able to run a new wire in using pin data in less than a hour. i would get that donne 1st b4 doing anything else

[tampenny]

Gentlemen,

GOOD NEWS

I've had a brake box out test (or something similar) done and I don't have wiring problem, hurrah !!

do have a sticking turbo actuator rod and a leaking intercooler tho'

am suffering from sticky brown trouser syndrome at the costs quoted by dealer

please please tell me some WD40 and RADWELD  will sort me out !!!!!

thanking you

[paul.h]

Radweld will not help with the leaking intercooler since the turbo air goes on the inside and the outside of it is air blowing through. It will be at the front of the engine bay and have large diameter rubber hoses going to it from the turbo and from it to the doser valve/inlet manifold. You may be able to spot the leak by oil staining/leaking out. Depending on where it is leaking, you may be able to seal it on the outside using a metal putty or weld/braze it up or go for a second hand one.

 

If the sticking turbo is due to carbon build up on the inside, then it might need removing for cleaning but there may be something you could inject to do this with it still in place. An internet search on turbo vane cleaner comes up with all sorts, but having never done anything like this I am not able to recommend any of them, but here is an example http://www.dieselturbocleaner.co.uk/

[citrophile]

Hi Tampenny

Can you confirm which model and engine you have. If it's a 2004 facelift then I suspect you have the 2.0HDI 136BHP engine, not the 2.2 which was on series 1 C5's.

In my experience turbo cleaners won't clean off large build ups of carbon and on the 2 turbos I have replaced recently (1.6HDI & 2.0HDI) ther variable geometry vanes inside the turbo were not clogged with carbon and moved quite freely even after 100k & 160k miles respectively. It's more likely to be the external actuator.

The inter cooler should be easy to check if it has a leak, just place it in a bucket of water and see where the bubbles come out. It might have obvious damage when you take it out but if not then should be possible to repair with metal type filler.

Rob

[tampenny]

Hi Rob,

it is the 2.2, series 1 C5 I have,

I'm sure you are correct about the problem being the external actuator,

is there any way to address this issue without replacing the whole turbo please ?

also how do you access the turbo ? it looks like a real pain to get to,

and finally do you think this would account for the very poor 20 mpg I am getting ?

being a Citroen owner is such fun....between the worry and sleepless nights !!

Thank you,

Mark.

[paul.h]

External actuators can usually be replaced on their own. Also check any hoses to the actuator are not leaking/split/especially at any connections.

 

If your 20 mpg is just round town driving, this may be normal for an auto. Try resetting the trip computer (hold in button on the end of the wiper stalk) and see what you get under different driving conditions.

[paul.h]

2.2 hdi 136 bhp turbo removal (it does not look as if the actuator should be removed with the turbo on the car):

 

1. Removing

 

ESSENTIAL : Do not separate the pressure regulation valve from the turbocharger or slacken its fixings.

Remove :

• The engine cover
• The battery style cover

Disconnect the battery negative terminal.

Remove :

• The air cleaner
• The engine subframe (see the relevant operation)
• The assembly of exhaust flexible / catalytic converter / particle filter

Remove :

• The turbocharger air inlet duct ,
• The turbocompressor air outlet duct,
• The bracket

Uncouple :

• The turbocharger oil supply pipe  (on the engine)
• The turbocharger oil return pipe  (on the engine)

Remove :

• The turbo/manifod nuts - 1 access from above the vehicle, others from underneath the vehicle
• The turbocharger (from underneath the vehicle)

CAUTION : Close the lubrication ducts and the oil return ducts on the turbocharger and the engine.

2. Refitting

Proceed in the reverse order to removal.

CAUTION : Check the absence of foreign bodies in the air ducts when refitting.

Tightening torque :

• turbo/manifold nuts to 25 ± 2 Nm

 

[tampenny]

does anyone collect spanners ?  as I now have another one in my works !!

having thought my ESP/ASR, limp mode, high turbo pressure, engine management light situation

was down to depollution filter/faulty turbo/actuator, I received the following info yesterday

after having some further diagnostics:-

 

permanent fault inside the ECU

PSA 9651212180

ECU add # 9639907180

Supplier MARWAL

D.Version FF

also:-

intermittent fault,

01,07,02,35

01,07,01,00

01,07,14,35

refer to related manual,

 

so I'm now convinced ECU is at fault

until someone told me that it is highly unlike to be ECU  

more likely to be sensors......!!!!

my brain is ready to explode,

can anyone please give me some guidance/advise on this ?

playing the C5 game is becoming less fun.

[hannah_gleeson]

does anyone collect spanners ?  as I now have another one in my works !!

having thought my ESP/ASR, limp mode, high turbo pressure, engine management light situation

was down to depollution filter/faulty turbo/actuator, I received the following info yesterday

after having some further diagnostics:-

 

permanent fault inside the ECU

PSA 9651212180

ECU add # 9639907180

Supplier MARWAL

D.Version FF

also:-

intermittent fault,

01,07,02,35

01,07,01,00

01,07,14,35

refer to related manual,

 

so I'm now convinced ECU is at fault

until someone told me that it is highly unlike to be ECU  

more likely to be sensors......!!!!

my brain is ready to explode,

can anyone please give me some guidance/advise on this ?

playing the C5 game is becoming less fun.

hi infact the ecu do play on on the c5, there is a company called "ecu doctor" based in plymouth and they seam to have alot of ecu  from c5s. if you give them a call they will ask if you could send the ecu to them and they will see if it has got any problems and also the cost in repairing it, i do have an ecu for a 2.2 hdi which is unlocked you could try that depending on what engine your car has,