I have been having a limp mode issue come and go for a while, but would always go away after restarting the engine. A while ago I tried cleaning the EGR (manually), Turbo (using a spray), and it *seemed* to help for a while, and would be less of an issue during warm months.

After 2 hours or smooth driving at around 70mph, I got into limp mode again, and as usual push-restarted the engine. A few minutes I noticed that cars behind me are keeping a large distance - noticed huge amounts of black smoke at 5-6th gear in particular. Tried to stay off the turbo and seemed to not smoke, but the car felt weird - I would feel a small jolt when taking the foot off the gas. Eventually check engine came on with P0100 (Mass or Volume Air Flow Current) P0404 (EGR Circuit Range/Performance) and my usual limp mode companion P0406 (EGR Sensor A Circuit High).

The final nail in the coffin was the car stalling when pulling away at a roundabout, and then really struggling to move. Just enough to pull off and call out AA.

While I was waiting I checked the intercooler pipe for any cracks as best I could visually and by feel - couldn't see/feel any cracks or oil. Neither did I notice whoosing sound while it was still running. Since I was waiting for the AA for 3 hours, I periodically checked oil level - it seemed to be at the miminum (same next day when I checked it at the garage again). Garage said it could be EGR or the Turbo, but didn't fix anything as I broke down in Ireland, and getting it towed back to Scotland.

All the people with shot Intercoolers/EGR valves do not seem to mention a drop on oil level. So I guess this must point to turbo? Does anyone have any experience with something similar? The oil drop seems concerning.


Annoyingly, just passed MOT a week ago with an advisory for rear shock absorbers!

 

https://www.jaguarownersclub.com/for...-acceleration/

 

Thanks @Dell Gailey , but they don't seem to mention drop in oil level which is concerning.

 

Not having a diesel version myself....It would appear you have a faulty EGR unit that is misreading its integrated positional sensor.
The 2.2L diesels have a different EGR arrangement from the 2.0L versions.
If your EGR sensor is sending the incorrect exhaust re circulation information, the engine management would likely be applying the incorrect fuel ratio into the engine as well which could give you occasional clouds of unburnt fuel.

If you were just getting a glow light error, then you likely would be cleaning the EGR, or checking spring returns etc, but sensor out of range codes imply a hardware failure.

No idea about your oil drop, apart from if you oil had taken on quite a bit of additional moisture over the winter months and then you do a good trip which evaporates that out, then you can sometimes notice a 'one time' drop in oil level as the system volume is reduced to actual oil.

 

Thanks @h2o2steam

I check oil level quite frequently, about 2x month or before long journeys (old car, so needs more TLC) and it was stable in the months running up to this. I was told that a failed turbo could spit out oil (not had much experience with judging smoke colour, so maybe it just looked black to me in the rear view mirror). A week later they still haven't towed the car back so cannot investigate further. I really hope it's just the EGR, but the oil drop keeps me worried it's something more involved that's broken.

 

https://www.fixya.com/cars/t808370-b...e_from_exhaust

 

Removed intercooler pipe - no cracks as farvad I can see/feel (photos as proof I actually did this). EGR seems cleanish (I did clean it about a year ago). However, I don't remember smell of diesel when I was removing intercooler pipe a year ago - is that a hint something is terribly wrong?

While I wait for insights from the forum, tomorrow I will focus on the turbo. Need to figure out how to test the turbo actuator (it moves up on start up, and moves back down on shut down).

 

Not sure if this would help diagnose the issue, but when I removed the turbo, I saw oil in the lower threaded holes where the exhaust manifold was attached. Could it be the oil seals in the turbo that failed?

 

Working away slowly at this, had the turbo and the actuator looked at by a specialist, he said turbo is fine an no evidence of oil leak in the turbo. So I went back to inspect the lowe elbow hose from the intercooler, and it was an absolute pain to get there (had to remove the front bumper).

I couldn't figure out how to disconnect the MAP sensor - didn't want to force it, and it seemed no matter how much I tried to squeze the plastic "retaining lever" it wouldn't budge. I managed to remove the lower elbow eventually (annoyingly, it wasn't cracked and the hose clip was fine...).

Anyway, just wondering if there's a trick to disconnect/remove the MAP sensor?