C4GP egs problems

[Liam11]

Hi and thank you in advance for all the help I may receive.
I am going out of my mind with this car.
I have a egs gearbox problem and I'm not really sure where to turn. Car is C4GP 1.6 hdi egs 2010.
About a month ago the clutch gave way so I went to a trustworthy recommended garage as I wanted the job done properly and got a new clutch kit fitted along with flywheel and was hoping that would be the end of my problems but it just led to more issues. Since getting the car back I now have noisy gear changes kind of like a clunk when it changes gear more noticeable in the lower gears. Occasionally I even get a grinding gear change going from 1st to 2nd. Also to note when using the kickdown or on a steep hill and it needs to change down a gear like 4th to 3rd for example it seems to just rev and loses it and seems to not find the gear and might end up changing down twice or not at all and I have to pull over and start again.
What is going wrong?
I have spent thousands on this car in the past 6 months and simply do not have anymore money to throw at it.
It has had new timing belt kit and pulleys, tensioner and aux belt. All new engine mounts, new suspension, drop links, ball joints, new clutch kit and replacement flywheel.
I am about to invest in a lexia kit to do any work myself but I need to be doing the right thing as I simply can't keep throwing money that I don't have anymore and not getting anywhere.
I am desperate at this point. The car is unusable and I really need to get it back to a usable condition.
Please any help is very much appreciated, I just want to be going in the right direction and get this fixed.
Thank you.

[GiveMeABreak]

Were the garage you used aware of the essential procedures required after change of clutch / flywheel?

After refitting the clutch or the hydraulic bearing, the diagnostic tool is required to:

• De-pressurise and bleed the hydraulic circuit
• Reset the clutch cycle counter to zero (only if replacing the clutch mechanism with a new one)
• Initialise the clutch bite point

Failure to do this will result in poor gear changes and problems.

If they were not aware of it, that doesn't say a lot for the garage to be honest - I would take it back and get them to do the job properly. If they don't have the correct diagnostics or tools to do it, then I'd get it towed to the dealer, pay them for the calibration and procedures above and get the garage to pick up the bill including towing charges.

[Liam11]

Hi and thanks for the reply. Im fairly certain they're aware of this as they are supposed to be egs specialist. This is mostly what they work on.
I took it to DK motors in Boston Lincolnshire.
I have spoken to the garage and they are adamant they have done everything correctly and told me it is likely to be the egs but I am sceptical to be honest at this stage after already spending thousands.

[GiveMeABreak]

If you had the fault codes from a diagnostic, along with your VIN, I could probably help you with those to see what the issue is.

[Liam11]

I don't have any codes at the moment. I only have one of those cheap obd readers which doesn't bring anything up. Currently waiting for lexia unit to arrive so I can hopefully get deeper into the system and see if anything comes up.

[Liam11]

Hiya mate
So I've received my lexia kit and got diagbox installed on laptop and plugged the car in and found some faults.
I got the codes p1800 and p0925. I've included pic of this.
First code indicates the garage may not have fully completed the initialisation and calibration of the gearbox and new clutch etc but could that have also caused the p0925 fault or could I also be looking at another issue altogether.
Thank you very much for your help.

[RichardW]

You need to drill down into the fault to see what it is saying about the captured data. I'd be very surprised if DK didn't do all the necessary programming after install of the new clutch.

[Liam11]

This is everything I got from the diagbox. I've attached pics of the data it gives.
Thanks

[GiveMeABreak]

Code P1800 suggests it wasn't carried out.

Fault Code:	P1800
Description of Fault:	Gearbox programming incomplete or not carried out fault : Not characterised. Selection gate initialisation not completed or not done. Context of appearance of the fault code: The following conditions have to be met: - ECU woken up - Ignition on for more than 5 seconds
Conditions for Fault to clear:	-
Downgrade Modes whilst Fault is active:	Automatic mode deactivated Crawling deactivated Take-off deactivated Gear change prohibited Switching on of the warning lamp and/or warning message (*): "SERVICE" warning lamp Sport warning lamp Snow warning lamp Automatic or 6-speed piloted manual gearbox warning lamps (Orange PRND triangle) Display of a "-" on the fascia panel
Symptoms:	Impossible to make the vehicle move Lack of power Difficult/impossible to change a gear
Suspect Areas:	Programming to be carried out in after sales

Fault Code:	P0925
Description of Fault:	Gearbox fault - The gear does not engage : Not characterised. Non-engagement of the gear requested at the end of 2 s (Not N). Context of appearance of the fault code: Gear change in progress (Engagement only) Technical precision on the context of appearance of the fault code: Absence of fault codes P1586 - P1587 - P1724 - P1726 - P1731
Conditions for Fault to clear:	After switching the ignition off and then back on
Downgrade Modes whilst Fault is active:	Attempts at engaging the target gear and activation of manual mode (Gear change requests are then ignored) In the event of a failure to engage the target gear: - Emergency selection of neutral (Subsequent gear change requests are taken into account) - Automatic mode deactivated if engagement of target gear fails In the event of failure after several attempts: Selection of neutral If the vehicle has the Stop and Start system: Stop and start function deactivated Switching on of the warning lamp and/or warning message: (*) Warning lamp MIL
Symptoms:	Difficult/impossible to change a gear Lack of power Absence of automatic stopping of the internal combustion engine Lighting of the engine autodiagnosis warning lamp Starting problem Timing Leaks
Suspect Areas:	Clutch kit Gear engagement sensor Selection sensor Electrical harness Pipes Hydraulic valve block Electro-pump Pressure accumulator Electrovalves Piloted manual gearbox Mechanical problem (Gear selection mechanism, Gear engagement fingers) Gearbox mechanics (Internal control)

(*): According to equipment and engine.

[Liam11]

Thank you for that mate. A lot more helpful than what I've found online which seemed conflicting so a big help. At least I'm actually going in a direction to getting it sorted.
I've had to park car up untill this is sorted.
What would you suggest is best cause of action?
I'm still trying to get my head around this diagbox as I'm all new to this to be honest. I've done all my own repairs on cars before but never gone into diagnostics like this before.
Should I try to do the initialisation process and see if that sorts it or am I better off investigating this p0925 code first. Seems like that could be any number of things.
Thanks again for the help.

[GiveMeABreak]

Actually I would first ensure that the relative operations have actually been done. Here is a list of operations regarding the Clutch and what should be done:

Operations to be carried out using the diagnostic equipment.

Note: 1, 2, 3, 4, 5, 6, 7, 8: Order number of the operations to be carried out.

Operations to be Performed	Replacement: Clutch Release Bearing	Removing - Refitting: Clutch	Replacement of the clutch
Reading of the Counters	No OK	No OK	No OK
Writing of the Counters	No OK	No OK	7 (Reset the clutch cycles counter to zero)
Depressurisation of the Piloting Actuator	1 (Before replacement)	1 (Before replacement)	1 (Before replacement)
Pressurisation of the Piloting Actuator	2 (After replacement)	2 (After replacement)	2 (After replacement)
Bleeding of the air in the hydraulic circuit	3	3	3
Initialisation of the Bite Point	4	4	5
Programming of the Piloted Manual Gearbox Grille	No OK	No OK	6
Reinitialisation of the Programmed Values	No OK	No OK	4
Learning: Value of the Engine Torque Transmitted to the clutch	No OK	No OK	8

If it's all a bit confusing, then I would suggest you consider letting the main dealer sort it out, as these can be complicated beasts and it may be cheaper getting it done properly by an experienced dealership who probably deal with these all the time.

If at this point there remains a fault, they will at least be able to advise on what from their experience is the likely suspect (s); as you can see there is a comprehensive list of possible suspects from the P0925 code.

[Liam11]

Cheers Marc.
I'll have to wrap my head around it. It should make a good learning experience and hopefully make life easier for the future with this car and save some money in long run.
Either way I'm committed to sorting this out myself as I've already put thousands into this car over the past couple months and don't think my bank account can stomach dealership fees.
Cheers

[GiveMeABreak]

No problem, I totally understand, in which case then the above should help with the procedure and the correct order to perform them.