DonDownUnder's D3 dropping into Limp Mode

Hello.
Firstly I must apologize for the truncated method this problem was posted.
A bit of history. We had the same problem some 10,000km ago on our trip and the problem went away. When the disco3 goes into limp mode it just requires a lot of action to pull safely off the road, put in park, hand brake & restart/reboot and proceed again until the same happens again. If I read the fault codes after the event I get the 13 listed faults. If I clear faults and check again I get the audio system permanent as is no longer fitted. And a repeat happens if I get limp mode again. It happened about 12 times and is very daunting.
I started getting the limp mode again after filling with fuel from an outlet at Croydon in outback QLD, Tank took about 60ltrs. This is the only significant event I can relate to where something has changed or is different. I finally overcome the limp mode by driving in sports mode in 3rd and 4th gear only keeping engine revs between 2300 and 3000. (cruise control never used).
Questions, low fuel rail pressure? Faulty fuel pumps (HP & Tank),fuel filters, waxy off-grade fuel, contaminated fuel, or just very cold fuel. Or am I missing things all together.
I have an aftermarket long-range tank fitted and hope to dilute the normal tank when we hit the road on Tuesday. I appreciate any help as I have a long way home.cheers Don

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Originally Posted by LandyAndy

I have sent Sniegy a PM alerting him to the thread.Ron does Dondownunder know his PM is here???
Andrew

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It looks like it.

ORIGINAL MESSAGE:
Hi, I am traveling with a 3300kg Caravan towing with a Disco3 v6 TD01/2008. Have had a lot of trouble with falling into limp mode in Outback QLD whilst sharing the skinny roads with Road trains and many times suddenly I stop, very unsafe and I can't ask a question on the forum. Very Sad when you need help, We are from outer west Sydney, long way to go, hope we make it. Fault codes via my Blackbox Nano :
'Any Clues please , Could a batch of bad fuel cause this?? Thanks

FAULT 1 OF 13
ECU: Instrument Pack
CODE:U0010
Medium speed CAN communication bus
(HISTORIC)

FAULT 2 OF 13
ECU: Instrument Pack
CODE:U0132
Lost communication with ride level ctrl module / Lost communication with suspension ctrl module A
(PENDING)

FAULT 3 OF 13
ECU: Instrument Pack
CODE:U0184
Lost communication with audio unit
(PERMANENT)

FAULT 4 OF 13
ECU: Engine Management
CODE:P0087
Fuel rail/system pressure - too low
(INTERMITTENT)

FAULT 5 OF 13
ECU: Engine Management
CODE:P0405
Exhaust gas recirculation sensor A - circuit low
(INTERMITTENT)

FAULT 6 OF 13
ECU: Engine Management
CODE:P000E
Fuel volume regulator control exceeded learning limit
(INTERMITTENT)

FAULT 7 OF 13
ECU: Automatic Gearbox
CODE:U2023
Control module network signal calibration data
(INTERMITTENT)

FAULT 8 OF 13
ECU: Parking Brake
CODE:U0100
Lost communication with engine control module/powertrain control module 'A'
(INTERMITTENT)

FAULT 9 OF 13
ECU: Ride Level
CODE:U0416
Invalid data received from vehicle dynamics control module
(PENDING)

FAULT 10 OF 13
ECU: ABS system
CODE:U0401
Invalid data received from engine control module/powertrain control module
(HISTORIC)

FAULT 11 OF 13
ECU: All Terrain Control
CODE:U0401
Invalid data received from engine control module/powertrain control module
(HISTORIC)

FAULT 12 OF 13
ECU: All Terrain Control
CODE:U0402
Invalid data received from transmission control module
(HISTORIC)

FAULT 13 OF 13
ECU: All Terrain Control
CODE:U0416
Invalid data received from vehicle dynamics control moduleu

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Originally Posted by DonDownunder

I finally overcome the limp mode by driving in sports mode in 3rd and 4th gear only keeping engine revs between 2300 and 3000. (cruise control never used).

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I would change the fuel filter because this sounds like a restricted filter whereby enough fuel can be delivered if demand is sufficiently constant. However you could first try draining the filter.

Not sure if this will help but the following is from the workshop manual:

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P0087-00 Fuel Rail/System Pressure Too Low - no sub type information

• Fuel rail pressure sensor disconnected
• Fuel rail pressure sensor to Engine Control Module sensing circuit short circuit to ground
• Fuel rail pressure sensor supply circuit high resistance
• Fuel rail pressure sensor failure
• Fuel line leak
• Restricted fuel line
• Fuel pump module circuit high resistance
• Fuel pump module circuit short circuit to ground
• Fuel pump module failure
• Volume control valve fault
• Pressure control valve fault

Refer to the electrical guides and check the fuel rail pressure sensor circuits. For fuel rail pressure sensor tests, refer to the relevant workshop manual section. Check the low pressure fuel lines for damage or restrictions. Check the fuel pressure. Check the low pressure fuel pump module circuits and operation. Check for fuel rail and high pressure fuel line leaks. Check for volume control valve and pressure control valve DTCs and rectify as necessary

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Quote:

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P0405-21 Exhaust Gas RecirculationSensor A Circuit Low - signal amplitude < minimum

• Right-hand Exhaust Gas Recirculation (EGR) sensor circuit low - signal amplitude less than minimum
• EGR valve position sensor circuit short circuit to ground
• EGR valve position sensor fault

Check the right-hand Exhaust Gas Recirculation (EGR) sensor and circuits. Refer to the electrical circuit diagrams. Using a data logger function, check the EGR valve angle. With the ignition on, engine off, command the valve actuator to 0% pulse width modulated (PWM), and then to 100% pulse width modulated (PWM) and recheck the EGR valve angle. The value should range from 0 - 20% to 80 - 95%. If this is not the case, install a new sensor. Clear the DTCs and test for normal operation

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P000E-21 Fuel Volume Regulator Control Exceeded Learning Limit - signal amplitude < minimum

• Fuel volume control valve amplitude is less than the minimum specified

Refer to the electrical circuit diagrams and check the fuel volume control valve and circuits. Check the resistance of the valve and install a new high pressure fuel pump if the resistance is not between 1.5 and 15 ohms (the fuel volume control valve cannot be serviced separately). Clear the DTCs and test for normal operation. Refer to the warranty policy and procedures manual if a high pressure fuel pump is suspect

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Quote:

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P000E-22 Fuel Volume Regulator Control Exceeded Learning Limit - signal amplitude > maximum

• Fuel volume control valve amplitude is greater than the maximum specified

Refer to the electrical circuit diagrams and check the fuel volume control valve and circuits. Check the resistance of the valve and install a new high pressure fuel pump if the resistance is not between 1.5 and 15 ohms (the fuel volume control valve cannot be serviced separately). Clear the DTCs and test for normal operation. Refer to the warranty policy and procedures manual if a high pressure fuel pump is suspect

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Edit the above would indicate low fuel flow. As Graeme has said likely issue is blocked fuel filter.

After reading the before & after, I am thinking along the lines of:-
Bad fuel has killed an injector/s,
Therefore killing high pressure fuel pump.

Does the vehicle repair itself for a short while (how many K's) then do the same?
Has any cleaning been done to the engine bay, before trip or while on trip?


CHeers

Hi I am having internet problems too,
Last drove D3 on Saturday. after reboot stop/start I would travel about 2 or 3k and bingo whilst in Auto with normal drive habits. (both cruising and accelerating < 2000 rpm . I then tried keeping engine revs above 2200 / 2300 and up to 3000 in 3rd and 4th gear in sports mode, I was able to travel at 80/85kmh for about 160k in this method without limp mode happening. I was not game to revert to driving in auto. Tomorrow Tues we head off and I have different fuel in reserve tank and was going to transfer and try in auto after a while & see if any difference. I have taken advice from Graeme's suggestions of a blocked fuel filter but I do not have a spare (fitted 15k ago) I opened the drain on the bottom of the filter and there was no actual flow , removed the valve plug completely and only Dieso was a damp covering. no water. At the first opportunity which should be Wednesday I hope to get my hands on a Fuel Filter. I will be in Charters Towers. No cleaning done under the bonnet. Engine oil/Filter change in Darwin no problems for over 2500k until fuel tank filled at Croydon immediately before setting off . Traveled about 50k before 1st limp mode . When running whilst towing ~~~ the engine runs smooth as silk, no vibration from any lazy cylinder or isolated injector fault. No loss of power when taking off with revs up . No irregular sound just the limp mode chimes when it happens. As I don't have a workshop manual can someone please give me the procedure for removal replacement of the fuel filter. I don't want to just assume its a screw on job and stuff it up, Also what is the procedure for priming and displacing any air?
Thanking everyone , cheers Don

Quote:

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Originally Posted by sniegy

After reading the before & after, I am thinking along the lines of:-
Bad fuel has killed an injector/s,
Therefore killing high pressure fuel pump.

Does the vehicle repair itself for a short while (how many K's) then do the same?
Has any cleaning been done to the engine bay, before trip or while on trip?


CHeers

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After you get things sorted, buy one of these, could save you having this issue again.

Mr Funnel

http://www.proquip.com.au/assets/Ima...0of%20flow.jpg

Mr Funnel Fuel Filter Funnels

Baz.

Transferred about 50ltrs from long range fuel tank, Drove 400+ Km today towing the caravan in Auto @ 85 ~ 90kmh and all is well, back to normal, Not jumping the gun but I think I got a batch of bad fuel. I will still change the fuel filter when I can source one. Are the Repco ones any good? and I will get one of those funnels Baz has mentioned.
cheers Don

I would suggest at this point in time that any brand of fuel filter is going to be better than what is currently on the vehicle.

Under normal circumstances I would not use a Repco one, but under your current circumstances I would use anything I could lay my hands on.