Diesel Information

TECHNICAL
MAY 2010
COMMERCIALLY CONFIDENTIAL DT466(EN)

Vehicle Electronics
EQUIPMENT: DW10TED4 Engines for Citroën, FIAT, Ford, Lancia, Peugeot
and Volvo Vehicles

SUBJECT: EGR Valve Adaptation After Replacement

1. INTRODUCTION

Vehicles fitted with the Euro IV variants of the DW10TED4 engines may suffer from several
problems if the newly fitted EGR valve is not re-adapted following replacement.

Adaptation enables the ECU to learn the open and closed limits of the new EGR valve, enabling
the EGR to deliver accurate recirculated gas back to the engine.

2. CONFIRMATION OF FAULT

2.1 Symptoms

If the EGR is not adapted the problems associated with this are the following:

• If the EGR is in the 'shut' position (Insufficient flow)

- Noisy engine

- Excessive emissions

- Illuminated Malfunction Indicator Lamp (MIL)

• If the valve is in the fully open position (Excessive flow)

- Difficult starting

- Noisy engine

- Excessive emissions

- Stalling problems

- Poor idle quality

- Hunting or surging

- Illuminated Malfunction Indicator Lamp (MIL)

DELPHI Diesel Systems Ltd, Diesel Aftermarket, Spartan Close, CV34 6AG, Warwick, England.
Tel: [44] [0] 1926 472 900 Fax: [44] [0] 1926 472 901 © Delphi
 DT466(EN) - MAY 2010 - 2 of 6

2.2 DIAGNOSING FAULTS

System diagnosis can be carried out using Delphi DS Diagnostic Tools.

The following diagnostic codes may be triggered if the new EGR valve is not re-adapted to the
ECU:

• P0400 Exhaust Gas Recirculation Flow Malfunction

• P0401 Exhaust Gas Recirculation Flow Insufficient Detected

• P0402 Exhaust Gas Recirculation Flow Excessive Detected

• P0403 Exhaust Gas Recirculation Circuit Malfunction

• P0404 Exhaust Gas Recirculation Circuit Range/Performance

• P0405 Exhaust Gas Recirculation Sensor A Circuit Low

• P0406 Exhaust Gas Recirculation Sensor A Circuit High

• P0407 Exhaust Gas Recirculation Sensor B Circuit Low

• P0408 Exhaust Gas Recirculation Sensor B Circuit High

• P1407 EGR No Flow Detected

• P1408 EGR Flow out of Self-Test Range

• P0490 EGR Control Circuit High)

• P1412 EGR Frozen

• P1335 EGR Position Sensor Min/Max stop Performance

2.3 VEHICLES AFFECTED

Note: Models are grouped according to whether they are supported or currently
unsupported by Delphi diagnostic DS tools.

CITROËN

Supported:

Model Details Model Year=> CC Power Engine Code

C5 2.0HDI 16V
2006=> 1997 100kW DW10BTED4
RHR/RHL
C5 2.0HDI 16V 02/2008=> 1997 100kW DW10BTED4
C5 ESTATE/
BREAK 2.0HDI 2006=> 1997 100kW DW10BTED4
16V RHR/RHL
C5 ESTATE/
BREAK 2.0HDI 02/2008=> 1997 100kW DW10BTED4
16V
 DT466(EN) - MAY 2010 - 3 of 6

Currently Unsupported:

Model Details Model Year=> CC Power Engine Code

C4 2.0HDI 16V
2006=> 1997 100kW DW10BTED4
RHR
C4 GRAND
PICASSO 2.0HDI 02/2007=> 1997 100kW DW10BTED4
16V RHR
C4 PICASSO
10/2006=> 1997 100kW DW10BTED4
2.0HDI 16V RHR
C8 2.0HDI 16V
03/2006=> 1997 100kW DW10BTED4
RHK
C8 2.0HDI 16V
03/2006=> 1997 100kW DW10BTED4
RHR
JUMPY 2.0HDI
11/2006=> 1997 100kW DW10BTED4
16V RHR
JUMPY 2.0HDI
11/2006=> 1997 100kW DW10BTED4
16V RHK

FORD
Supported:

Model Model Details Model Year=> CC Power Engine Code

KLBA
LPBA
2.0 TDCi 16v DPF 81, 85, 96, 100,
GALAXY 04/2006=> 1997 AZWA
(MKII) 103 kW
QXWA
QXWB
KLBA
LPBA
2.0 TDCi 16v DPF 85, 96, 100, 103 AZBA
MONDEO 03/2007=> 1997
(MKIV) kW N7BB
QXWA
QXWB
AZWA
S-MAX 2.0 TDCi 16v DPF 03/2006=> 1997 96, 103 kW
QXWA
 DT466(EN) - MAY 2010 - 4 of 6

Currently Unsupported:

Model Model Details Model Year=> CC Power Engine Code

G6DA
C-MAX 2.0TDCi 16V 04/2007=> 1997 81, 100 kW G6DB
G6DD
G6DA
2.0 TDCi 16v DPF 2006=> 81, 100 kW G6DB
G6DD
G6DA
FOCUS CC 2.0 TDCi 16v (MKII) 05/2006=> 1997 100 kW G6DB
G6DD
G6DA
C-MAX 2.0 TDCi / TDCi
2006=> 100 kW G6DB
DPF 16v
G6DD
KUGA 2.0 TDCi 16v DPF 04/2008=> 1997 100 kW G6DD
KLBA
S-MAX 2.0 TD/TDCi 16v 10/2007=> 1997 85 kW
LPBA

FIAT
Supported

Model Model Details Model Year=> CC Power Engine Code

88 kW RHK
SCUDO 2.0 JTD 16v 11/2006=> 1997 RHK
100 kW
RHR
RHK
ULYSSE 2.0 JTD 16v 05/2006=> 1997 88 kW
RHR

LANCIA
Currently Unsupported:

Model Model Details Model Year=> CC Power Engine Code

2.0 JTD 16v 88 kW RHK
PHEDRA 2006=> 1997
2.0 JTD 16v 88, 100 kW RHR
 DT466(EN) - MAY 2010 - 5 of 6

PEUGEOT
Supported:

Model Model Details Model Year=> CC Power Engine Code

2.0 HDi 16v RHR/RHL
407 COUPE 2.0 HDi 16v 2006=> 1997 100 kW DW10BTED4
SW 2.0 HDi 16v

Currently Unsupported:

Model Model Details Model Year=> CC Power Engine Code

2.0 HDi 16v RHR
307 CC 2.0 HDi 16v RHR 2006=> 1997 100 kW DW10BTED4
SW 2.0 HDi 16v RHR
2.0 HDi 16v 9HV 09/2007=>
308 1997 100 kW DW10BTED4
SW 2.0 HDi 16v 04/2008=>
607 2.0 HDi 16v RHR 2006=> 1997 100 kW DW10BTED4
2.0 HDi 16v RHR 06/2006=>
807 1997 100 kW DW10BTED4
2.0 HDi 16v RHK 11/2006=>
2.0 HDi 16v 11/2006=> 100 kW DW10BTED4
DW10BTED4
2.0 HDi 16v RHR 11/2006=> 88, 100 kW
EXPERT 1997 DW10UTED4
TEEPEE 2.0 HDi 16v DW10BTED4
11/2006=> 88, 100 kW
RHR DW10UTED4

VOLVO
Currently Unsupported:

Model Details Model Year=> CC Power Engine Code

C30 2.0 D/D PF 16V 10/2006=> 1997 100 kW D4202T
C70 2.0 D5 16V 03/2007=> 1997 100 kW D4202T
D4202T
S40 2.0 DiTD 16V 2006=> 1997 96, 100 kW
D4202T2
S80 2.0 TDi 16V 02/2008=> 1997 100 kW D4202T
V40 2.0 DiTD 16V 2006=> 1997 100 kW D4202T
D4202T
V50 2.0 D4 16V 2006=> 1997 96, 100 kW
D4202T2

3. SERVICE POLICY

Diagnosis for fault codes can be performed using any ODB II compliant system however It is
recommended that the EGR valve adaptation procedure is carried out using the appropriate tools.
 DT466(EN) - MAY 2010 - 6 of 6

We recommend:

• The customer should contact their local vehicle dealer for the adaptation process to be carried
out.

• Use of Delphi diagnostic DS tools in the adaptation process for the supported models.

It is recommended to replace the EGR valve with the O.E. equivalent part:

• EG10395-12B1 for Ford and Volvo.

• EG10396-12B1 for Citroën, FIAT, Lancia, and Peugeot.