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#12914 The Lightening Bolt Of Doom!

Posted by Briscoe76 on 08 April 2018 - 02:42 PM

Afternoon all.


I thought I would share a bit of a story that happened to me this weekend, in the hope that it will help some others if the same thing happens to them.


The model it concerns is any 300C with the Mercedes 3 litre V6 diesel. I'm guessing the newer models with the VM diesel will be totally different.


So there we are, on the way to Wakefield from Essex where we live, merrily trotting along the motorway. All of a sudden the dashboard starts to chime repeatedly (as if i've left the headlights on and got out), the engine cuts out completely, and on the dashboard are the engine management light, and the red lightening bolt, with a reverse bracket either side (see attached photo).


We coast to a stop onto the hard shoulder, and i try to restart the car. It turns over and over, but refuses to fire up.


The missus gets on the phone to the RAC, and we're told there's roughly a two hour wait, so this gives me a bit of time to do some Googling before the patrol arrives.


Now then, if you refer to the handbook, it clearly states (even in the diesel supplement) that the lightening bolt light indicates there is a fault with the "Electronic Throttle Control". This is utter nonsense. As it turns out, on the diesel models only, this light refers to a fault with either the Swirl Flap Motor, or the Turbo Actuator. Annoyingly this isnt listed in any of the handbooks that come with the car. Poor show Chrysler!


Whenever you turn the ignition on in the car, you can see the arm of the turbo actuator raise up. So if this is the problem, then its very easy to diagnose. I tried this little test, and sure enough, the turbo actuator arm wasn't popping up when my wife turned the ignition on, so naturally I thought this was the problem. Sadly I was wrong.


What had happened to my car was this....


Over time, the seal around the air intake on the front of the turbo degrades. This allows a small amount of oil to drip onto the swirl flap motor, which is situated directly below. (very poor design). This oil had eventually seeped inside the motor, causing it to short out. This short had instantly popped fuse number 15 under the bonnet, which in turn had caused the engine to shut down while doing 70mph to protect itself. I didn't have the handbook in the car with me sadly, so searching on the internet just have me fuse diagrams of the petrol models, which on those shows its for the injectors. Again as it turns out, fuse 15 in the front fuse box does completely different things on the diesel models. It protects the following.... A/C Clutch, A/C Pressure regulator, Crankcase Vent Heater, EGR Valve, Engine Control Module, Fuel Pump, Glow Plug Module, Swirl Flap Motor, Oxygen sensors..


So I replaced the blown fuse with a spare 20 amp, and the car fired straight up. It was now in limp mode, and showing the EML and Lightening light, but it was drive-able up to about 80 mph, albeit a bit slow getting there.


By this time, the RAC man had arrived. Now there is nothing worse that someone interfering when a pro is at work, so when he arrived, I left him to it, and he plugged the diagnostics in, and it threw up a ton of errors all related to things connected to this fuse. All except the swirl flap motor. He was a bit confused at first, but then I mentioned that I think it might be the swirl flap motor. He hooked up all his testing gear to it, ran a load of tests, and sure enough confirmed to me that the motor was dead.


He then cleared the ECU codes, started the car, and only then did it throw up a specific Swirl Flap related error.


HE gave me some spare fuses, and after a quick road test, we were on our merry way albeit in limp mode.


Now to fixing it.


The cheapest place I could find to supply and fit a new motor quoted £575 plus VAT. The motor is just over £100, but the labour involved is a joke. Anything that is situated inside the VEE of the engine (Swirl Flap Motor, Oil Cooler) etc needs major open heart surgery to fix it. Annoyingly both the motor and the cooler seals have known faults, so they couldn't be in a worse place!


If you fancy forking out all that money to have the motor replaced, then that is no doubt the best way in the long run, however there is a quick fix for £1.99 and YES it does work perfectly.


Get yourself some 4K7 resistors off of ebay, they are £1.99 for 50. Remove the engine cover, then remove the intake pipe that runs from the airbox to the front of the turbo. Right below the turbo, you will see a black box. This is the offending motor. On the right of the motor is a multi plug held in with a grey clip. Remove the metal bracket above the plug, and pop the plug off.


Grab a resistor, and bend the legs in such a way that they will fit snugly into the two centre holes in the plug. Theres 4 in total. Once you have put the resistor in, and you can confirm its in there properly. Tape it up with electrical tape so the resistor wont fall out. Replace the metal bracket, and the air intake pipe, leaving the plug sticking up so you can get to it again in the future if you need to. Then start up the car, and stand back in amazement as both the engine management light and the lightening bolt lights extinguish, and the car comes back out of limp mode.


Take the car for a drive, and you will see that it drives as good as new.


What you have done here, is fool the car into thinking the swirl flap motor is working again. WHen in fact its now disconnected.


You shouldnt notice any difference in performance or fuel economy at all. The emissions may be up slightly when cold is all.


So to summarise, if your car cuts out with the lightening bolt on.


1) Coast to a stop

2) Curse, swear, have a fag, but don't despair

3) Check fuse 15 in the front fuse box, and replace

4) Start the car and drive home in limp mode - The car will do upto 80mph

5) Order your resistors from Ebay, making sure they are the 4K7 type

6) Still use your car while you are waiting for them to be delivered, remembering that it wont pull away as quick as usual

7) Fit the resistor at the weekend in the rain

8) Stand back, chest puffed out, hands on hips, telling the neighbours you've just saved almost 700 quid :-)







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#857 Known Issues And Faults

Posted by soulie147 on 14 August 2014 - 02:07 PM

Electric Windows seem to be a bit of a bone of contention.


Don't let a seller tell you  "It's probably just a fuse"  if one of your windows doesn't work,  there are no fuses.


I have spoken to a couple of other Voyager users and they say the same.

Keep the window tracks oiled so there is no resistance for window going up and down.

Seems once the tracks either end dry up,  the motors slow down and that's when problems can start.

I use some 3 in one oil,  not WD40,  and my once slow windows now nip up and down.


Just a thought!!

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#16339 Hi! I'm Back!

Posted by vincey832 on 11 May 2019 - 08:19 PM

Yes Nello, it is a Limited, cream leather interior, heated seats but not electric which I find strange, changed the cabin filter today the one that came out was FULL!!! huge sunroof which also was unexpected, I thought it was just a panoramic roof!

My 500X returned 48mpg in town driving and Yes sport mode is entertaining, have you found the 'G' meter??

Sorry the interior photos are poor.Delta.jpg Delta1.jpg Delta2.jpg Delta3.jpg

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#16293 On Autotrader; 1.4 Sr Only 16K Miles

Posted by Deltamike on 06 May 2019 - 06:37 PM

Hi, hopefully this car is going to be mine!  The low mileage is due to it being a Guernsey car, so low miles but perhaps a bit more clutch abuse.  I've put a deposit on it, just waiting now for the dealer to get a UK registration & MOT for it.


I would say it hasn't seen many harsh winters and salty roads etc., however I suppose it has lived in a coastal environment as Guernsey is so small you can't really get away from the sea.  I couldn't find any corrosion though, there's a tiny mark on the n/s/r bumper up where it meets the wing and signs of it being stood about (leaves & cobwebs around the under bonnet scuttle area etc) but other than that the exterior is lovely, the wheels & interior are pretty much immaculate.


As a long time Lancia fan & owner of an original Delta this one will be getting the re-badge treatment to remove the C-word!

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#8703 Surplus Spring Coils For Free

Posted by Dido on 25 August 2017 - 07:04 PM

This forum has proved indispensable for a Delta owner.
I had the misfortune of a snapped passenger side spring coil, originals come in pairs with a hefty £300 price tag. I am going for an advice I got from the forum for a suspension lowering eipache kit been backed and shipped and hopefully by next week will be fitted OK.
I will have surplus driver side and the 2 back ones old and bit rusty of course (11 reg) but can solve a problem and get a Delta back on the road.
I can find some space in the garage or the attic to keep these in case a mate in the forum needs them, can ship for what it costs.
Do you think we should set a spares thread....
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#17124 On Autotrader; 1.4 Sr Only 16K Miles

Posted by Deltamike on 20 October 2019 - 02:44 PM

Got home from the rig and the nice people at Swansea have written to me.  So right now I am the proud first ever owner of AP12 VXC!


Weirdly the V5 says 'first used elsewhere in the UK', which - if you've been following this - we know is B-S & is what caused all the faffing about in the first place; Guernsey isn't in the UK or EU.


Never mind, tomorrow will transfer the GAS plate over & that is finally that!


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#16421 Hi! I'm Back!

Posted by vincey832 on 27 May 2019 - 12:12 AM

20190525_153725.jpg Delta4.jpg   My Saturday was full on....

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#16222 New Delta Owner

Posted by Lampard on 16 April 2019 - 07:19 PM

Hi . I’m the lucky person who now owns Mikeys Delta. Just got home from collecting it .Mikey has maintained and looked after D3LTX. I have a file 2 inches thick listing everything he’s done .Really nice drive and a credit to him.
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#16022 Sexy

Posted by 7up on 14 March 2019 - 08:07 PM

flip sake, thought it was just me.
Just wasted half a bottle of aftershave.
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#15954 Sliding Doors Problem On Mk5

Posted by karmannski on 06 March 2019 - 08:16 AM

Hi all, 


I managed to fix the issue and hope that it will help some of you in the future to save some stress and money. 


The problem was bad ground wire G300 that lives under the carpet next to the B pillars on each side of the car. 


You must remove plastic covers and lift the carpet, undo the wire and give it a good clean. 


I found this video for similar problem, that might help you to picture it. 






Hopefully this is it and I wont have this problem any more. 






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#15647 Delta Active Suspension

Posted by Dorian on 08 January 2019 - 12:12 AM



Sorry for loooooooooong time to answer. If you wont to go lowered on active susp. Just replace springs nad thats all. Dont touch anything on cpu. Replace spring and njoy





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#15457 Sump Plug And Washer

Posted by Josboogz on 02 December 2018 - 09:47 PM

Just to confirm got my Delta services and MOT by my local indie. Sailed through MOT:)

Sump plug and washer from mito from Alfa workshop was fine.

Spark plugs were also right, car feels a lot better a lower revs.

Glad I got it done, thanks for the advice chaps
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#14366 Alarm Going Off Whilst Driving!

Posted by Rossocorsa on 21 July 2018 - 12:02 PM

Fixed at last! Got a new siren/control unit off eBay different part number but just the tone of the beep seems slightly different £80 as opposed to about £200 from Fiat, didn't want to risk £200 on something that may not have fixed it! The reason for failure of these units seems to be neither battery failure nor damp. The unit is sealed against damp but this has the side effect of holding in very small amounts of corrosive fumes from the charging of the batteries and this corrodes the circuit board. That's the theory I found on the net and seems plausible
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#14001 Self Bleeding Brakes?

Posted by gordy on 19 June 2018 - 08:48 PM

May I add something here after readig it....Ahhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhh F/n Helllllllllllllllllllllllllllllll....Sorry....

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#13697 Cutting Out, Engine Warning Light Intermittent, Garages Finding No Faults?

Posted by Bexb8818 on 21 May 2018 - 07:29 AM

Thanks again everybody - such a knowledgeable forum!! The cars been running absolutely fine since the repair and my paranoia has also calmed down ha! So far so good x
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#13009 The Lightening Bolt Of Doom!

Posted by Briscoe76 on 13 April 2018 - 03:11 PM

Hopefully this will be of some use to someone if the same happens, which sadly I believe it a common thing :unsure:.


I've had the resistor in place for a week now, and its been working perfectly. About 300 miles covered faultlessly. It was playing on my mind about the whole thing being held together with electrical tape, so I decided to buy the ready made part from the chaps at www.custom300cshop.co.uk


Its the second time Ive used them, and they are really helpful, with fast deliveries.


The part I ordered was the swirl flap emulator




Its basically a resistor fitted into a purpose made, and very high quality plastic casing, which fits perfectly into the swirl flap plug. This should take the worry out of the electrical tape melting or degrading over time. It was £40, which some may say is a lot for a bit of plastic, however the fact that they have had these specially made, they fit perfectly, and they are a damn sight cheaper than a new swirl flap motor, I think its good value for money.


Pictures below if you fancy a look.





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#10388 1St Post, Need Help With Starting/cutting Out Issues.

Posted by SJC on 31 January 2018 - 08:55 AM

So garage have fitted 4 new injectors, and it so far so good. They have tested it and cannot replicate the cutting out. I have only driven it short distance, but it starts well (when previously it didn't) and it hasn't cut out, when previously it might have.


If anything changes I will get back on here, but for anyone else who is experiencing poor starting and cutting out here is the order of events for me:


  • Fuel Filter
  • Pressure relief valve
  • Fuel filter housing and wiring loom
  • Pressure sensor on fuel rail
  • Injector testing
  • New injectors


My car has been renamed Triggers Broom!

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#10117 My Delta Review Has Just Been Published :-)

Posted by MikeyRules on 16 January 2018 - 02:48 PM



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#5912 2.5 Crd Thermostat - Sealed Unit Or Not?

Posted by Argee on 06 November 2016 - 11:54 AM

Did it!!
Excellent video andyb2000 thanks!
I found out that the thermostat I bought was actually mis-labelled in the database and was for an earlier voyager variant.

I didn't fancy waiting for 2 weeks for delivery of the ebay thermostat that andy mentioned in his youtube notes so I did a little research on similar types.

I picked up a thermostat for a 1992 Renault Clio 1.1 Engine code C1E700. It was about £8.  It didn't have the same housing as the one Andy used, but the disc type.  I had do do a fair bit of filing to reduce the diameter.
It works a treat!  

Thanks all for your help.

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#191 Recommended Oil? (2.8 Diesel)

Posted by a1ant on 24 April 2014 - 07:43 AM


5w 30 fully synthetic oil is recommended for your 2.8.

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