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Limp mode won't pass 3.5k revs

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35k limp mode revs
6K views 28 replies 7 participants last post by  Soldiiier 
#1 ·
I know this topic has been done to the death.

But I've fitted a second hand (low km) inlet manifold, EGR has been cleaned and fitted with partial blank in plate. (No one can do the full blanket in Australia)

Started a long journey from Melbourne to Sydney.
First 300km perfect.
After that I started the car and let it idle with the air on running for a bit for the mrs, I left for 5 minutes, came back and EML was on.

I continued the journey, but the car wouldn't pass 3k revs. I tried to keep revs high for the next 5 hours of driving, thinking that am auto regen would kick in, or my driving would be enlightened to manually regen if this was the problem.

No luck, had to keep driving. After about a total of 800 km of driving I got the hill holder/vdc fault on the dash and fuel gauge was on 0. Pulled over as soon as I could and fiddles with the injector wires because I have re done 1 4 and 5. Vdc/hill fault cleared. But engine light and 3k revving problem is still there.

I was reading another thread that said to disconnect the maf sensor and see if it'd still then same?!
 
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#4 ·
The EGR can still fail with the blanking plate on, I'd try the coke can trick, will get you home, and tell you if it is the issue or not.

If the is little power, and engine is reading 0 fuel, 'might' be an issue with the pump in the tank ( try fuse f21) as the fuel sender is on this often.

If you want a full blank, your best bet is one of fixitsan's dongles, am sure they can be shipped over.
 
#5 ·
I'm thinking it may be an issue with the blanking plate.

What's the coke can trick?

Trouble is, I'm 1000km away from home, and about 700 km from the end of our journey

I fixed the fuel reading, by fiddling with injector wires

Still having the rev restriction at 3-3.5 revs, and struggling on climbing hills, power below 3k revs seems to be normal

No where near anyone to do EML readings :s
 
#7 ·
Blocking the EGR does not create a limp mode. Just an EML. But if the EGR dies you will still loose performance (but not as bad as with no plate), the same thing happened to me.

COke can trick is to cut out a bit of the skin, and slip in under the EGR (blocking the pipe going in the bottom). If it is the issue will get you home, but don't rely on it for a long time.


If you have fuel in the tank, and it's reading 0, would suggest that is a significant lead

Also have a look at this thread, check your pipes and box on the front panel.

http://www.alfaowner.com/Forum/alfa...der/367560-power-loss-with-diesels-guide.html
 
#8 ·
The EGR isn't completely blocked. I've got the partially blocked plate with the drilled hole.

The fuel gauge is working good now. It was just an intermittent wire into the injector.

Stil can't pass 3k revs

This only other times I've been limited to below 3k lasted very short periods of time and on next start or within 10 minutes full power would be restored.
 
#10 · (Edited)
Try disconnecting the MAF sensor, often shows it's effects over 3k rpm.
Think we've been misled a little by talks of blanking plates, a duff EGR usually shows it's effects below 2k


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#12 ·
Can u guide me to the maf sensor? I was planning to locate it tomorrow and disconnect / possibly clean it. And see how that goes.

Have you had the fault codes read? If not why bother guessing?
The problem occurred 300km into a 3 day/1800km total trip. With my wife relocating across the country. I didn't have the luxury of being able to goto my mechanic or find anyone who could in a new town.


Now I have arrived at my destination and it's a Sunday. Starting new job on Monday, so was hoping to get pointers instead if twiddling my thumbs and possibly making it worse for my self.

Thanks for the responses guys
 
#21 ·
found someone who could read the codes,

came up with P2013

the guy I bought the inlet manifold off was getting the same error with this inlet manifold.

the mechanic who installed this inlet manifold said the swirl flaps on it were fine, and that this error points to an actuator fault. the actuator was not changed over, so i am using my pre-existing actuator from my old manifold. I did see the movement of the flaps prior to installation and they seemed to move as you would expect.

mechanic advised me to check the connections to the actuator and clean the terminals, where can i find the actuator?

thanks
 
#24 ·
from the pierburg documentation:

Important note
Electric drive modules are capable of "learning":
After having operated the ignition several times, the electric drive modules are "set up" irreversibly matching the intake manifold to which they are fitted

for this reason when exchanging the intake manifold, also the electric drive module must be replaced by a new one
The "old" drive module can no longer be used
i used my existing actuator, so im thinking as it says, that the old actuator wont work.
it took about 5 starts for the EML light to come on, and hasnt gone since, even with a forced reset of the code

does anyone know how to reset the adaptive settings on the ECU?

thanks
 
#27 ·
yeh, I find that after you disconnect it, just try and open a door or something, the demand on the light should drain any residual power away.
 
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