ECM/BCM Fault Codes
 

Our 2009 1.6D is showing a few fault codes scanned with VIDA:

BCM-0101 Communication between control units Communicational problems with ECM
ECM-6720 EGR control - Flow too high
ECM-3000 Camshaft position (CMP) sensor - Faulty signal
ECM-4477 EGR control - Flow too low
ECM-4490 EGR valve - Signal too high

The history:
The car ran with a lumpy idle and occasional power hesitation and displayed a code stating that the EGR was jammed. As a result I replaced the EGR valvle with a Haas par from Eurocarparts. I cleared the code, reset the EGR in VIDA and all seemed well for about a week. Following that the problems re-emerged coupled with "Anti-skid service required" message on the dash.
The anti-skid message appears and disappears randomly but mainly when its wet. The codes above reappear if cleared after some time.

I have also put the car on new suspension all round since these problems started as the service revealed 2 broken coil springs. At 9yrs old and hoping the car will last us another 2yrs I replaced all shocks, top mounts and raised the ride height using standard Sachs springs (heavy duty at the rear) instead of the DRIVe spec lowered springs. I have no idea of that's contributed to any of these errors but would hope not.

What next?
Well there's the question. Part of me wonders if I should write the Haas EGR valve off as a bad idea and replace with a genuine Volvo part. Pricey at £214.
I'm a little worried that it might not be the culprit and that I end up throwing good money after bad. Any thoughts?

Anyone? Failing some insight it's off to either Volvo or Webuyanycar. I'm at the tipping point with this one.

Did you disturb any of the wiring to the ABS sensors while refurbing your suspension? If the signal or one of the sensors are dirty that read one of the ABS rings this could cause the Anti Skid issue.

TT

Hard to say as my local garage did the suspension but it was throwing the anti skid faults prior to having the suspension overhauled. Initially I hoped it was the broken springs causing minor differences in readings that was causing it but looks unlikely.

I took the ECM out last night and cleaned all contacts with contact cleaner, refitted and all codes cleared and I'll see what reappears before taking any further action. I'd quite like to get rid of the car but my wife loves it so it looks like it's staying for the time being.

So after no viable alternative being obvious I replaced the 6 month old Haas EGR valve from Eurocarparts with a Genuine Volvo one.

All looks good so far. The car is way up on power with no hesitation between 1-2000rpm and a few test runs later there are no logged faults when scanned with VIDA. Fingers crossed the problem is solved but my wallet is now and additional £250 lighter.

Yet another sterling example as to why original Volvo parts are so much better than other branded after-market parts

Fit original; and you buy once and fit once, and you know it's right

You're right, and in general I agree, but it's also another example of why I'm gradually going off Volvo. There's no valid reason why an aftermarket part like an EGR valve shouldn't be easily replaced with an aftermarket part but Volvos seem to be almost set up to make it difficult for aftermarket parts to be used or accepted by the car's electronics.

The Haas valve was under £100. The Volvo equivalent was £250 and that's a re-manufactured part involving exchange of the old one. Lord knows what they charge for a non-exchange part. Volvo prices are OK for some parts such as batteries but for some other parts are sheer extortion and coding things like throttle bodies to cars is outright protectionism.

The parts guy at our local dealer is constantly apologetic for the price of OEM parts especially when many parts for the S40/V50 are re-badged Ford parts often at twice or three times the price.

Out of interest, did you have them side by side at any point? Was there any difference in quality?

I'm all for gen parts for something so simple I wonder quite often how different can they really be, it's just an electronic valve....

I wouldn't be too surprised if your problem is still there, it just hasn't shown itself again yet.

They looked identical side by side to be honest and you'd be hard pushed to spot a single difference but clearly the electrical signals sent and received by the ECM weren't the same despite running the adapt new EGR function in VIDA after installation.

The EGR jammed error afflicted the original genuine Volvo EGR even after cleaning and the signal too high and too low errors manifested almost immediately after clearing the codes with Haas one. The new one, so far, shows no sign of repeating the error but I'll continue to monitor it and run regular fault scans to check.

Hi,

Did your replacement EGR fix your issue long term? I have an s40 1.6d that is producing the same codes via vida. my plan is to remove the egr and clean it out as a first port of call.

if that doesnt fix then a replacement will need to be something i consider, the car is actually one i have to sell, i've bought an xc70 to replace it but i cant sell it with errors on the dash and reduced performance. well not unless i sell it for peanuts, its a nice car in good condition outside and in so i'd rather spend a little bit of effort to get it to a nice saleable condition.

I didn't buy it to sell ive had it for 2 years but fancied the xc70 as its such a nicer car and what i consider a proper volvo. the s40 always felt like a ford in disguise to me. but if i can sort it will be a nice car for someone never let me down.