Hi all, yep, the car is playing up again!

Since having the new wheel bearings and CV joint fitted I have had a few issues...
Firstly, the rear wiper has stopped working, unless you give it a thud then it works once. But it was getting slow anyway so I think its just a coincidence. But...

The EML light has come on and my basic code scanner points to a P2102 code ' Throttle Actuator Control (TAC) Motor - Circuit Low ' and has been running on a few revs/shuddering after turning off. I have also had an intermitted P2100 code ' Throttle Actuator Control (TAC) Motor - Open Circuit ' too.

Now, when the wheel bearings were done the mechanic noticed the Pad low warning had been unplugged from the pads. I think this comes back to when I hit/ran over a lorry tyre which ripped the under-tray off etc. So he plugged this back in, I'm just wondering if he had to give it a bit of a tug to get it to reach and that in turn has stretched/broken a wire? As I took the EGR and ASV apart today and the ASV moves fine, no resistance, the cogs sound like they are making the correct sound too. The EGR on the other hand was reasonably stiff to open the plunger, but I cleaned it all up put it all back together and the first time I turned it on/off it worked as good as new with no EML light. Next time around, same problem again.
I did notice the plug for the ASV doesnt clip on at all, it is just a gentle push fit it seems, this is what made me wonder if the wires had been pulled on the loom. As the 'circuit low' and 'open circuit' warnings sound to me more of a connection issue than the actual part??

If anyone can advise how this can be checked, and also, if its ok for driving then please let me know. The car seems to run fine (if slightly gutless compared to what im used to at low revs) but id assue itll be in a limp home mode rather than running the full stage 1 map.

EDIT: just as a small addition that I forgot, if I turn the ignition to position 2 (but don't start the car) I can hear a sound, a bit like the fuel pump prime, but it goes on for about 5-10 seconds intermittently buzzing at slightly different speeds, could i be me hearing the cogs in the ASV moving as the wire has an intermittent connection?

Edited 30 September, 20196 yr by robt100

Nobody??

I was hoping someone may have half an idea, as if its a circuitry thing, I don't want to really be spending £200 in parts just to be exactly where I was before! MOT is also due in 6 weeks, so needs doing sharp-ish

I'll have a think about this later, PM me a reminder if you don't see anything.

The retaining clip on the connector will have been broken by someone trying to undo it, rather than wires being pulled, 99.9% certain.

On 30/09/2019 at 17:28, robt100 said:

The EGR on the other hand was reasonably stiff to open the plunger

That's normal, there's a strong return spring to make sure it shuts fully when not being lifted by the vacuum diaphragm.

Thats good to know, it seemed normal, but best to ask. Though im still unsure whats going on with the ASV, does anyone know where I could find a pin-out label for the plug? Just to see if Im getting constant voltage etc.

4 minutes ago, robt100 said:

anyone know where I could find a pin-out label

Your engine code is a crucial piece of information in getting to the right wiring diagram.  If you don't know it, it should be on the data sticker in the boot, near the spare wheel well.

Year the car was made is also useful.

late 2005 build BKC engine 1.9PD. More detail needed?

On it now, won't be a minute.

Pin 1 at V157 brown wire, earth

Pin 2 blue/red wire, from fuse 24 in E-box

Pin 3 purple/green, comms connection to engine ECU pin 60 of 60-way connector

Pin 4 purple/yellow, comms connection to engine ECU pin 25 of 60-way connector

Thanks @Wino I shall get onto that tomorrow!

Ok, so tomorrow seems to have now become 6 weeks

Got the car through the MOT, deleted the EML codes and hoped for the best, thankfully they didn't come back on again till after the test!

But just before the MOT whilst having some other work done, we did a deep scan of the ECU, it seems there is open circuit faults on the ASV, A/C pressure switch and rear wiper.....is there any common Fuse/Relay/Earth/loom section that these all use? I'm just thinking that maybe there is a chafed wire, or a dodgy relay somewhere etc. Maybe @Wino might have the answer?? (I just hope its not the 60pin ecu connector!)

No, I'm afraid they all look unrelated, at a quick glance.  All sound like common failures though.

Does the radiator fan work normally? That seems to share the ASV's ignition switched feed from E-box fuse 24.

Edited 26 November, 20196 yr by Wino

On 26/11/2019 at 11:34, Wino said:

No, I'm afraid they all look unrelated, at a quick glance.  All sound like common failures though.

Does the radiator fan work normally? That seems to share the ASV's ignition switched feed from E-box fuse 24.

Possibly not. Will try and check though in these temperatures who knows if it'd turn on. But.... due to an incident with a stray lorry tyre the whole radiator mount system has shifted back on one side, so the fan has witness marks where it has rubbed on the Air con piping, so maybe something has gone there that is related to the ASV. Fuse 24 looks ok though