XC90 Limp Mode - EGR cleaned but fault is back..

[SweetAs]

I have a love hate relationship with this vehicle. I love it when it works but could set fire to it when it doesn't.

Its a 2003 XC90. 2.4

We have had an intermittent limp more problem for 12 months now. Ive changed turbo hoses, MAP sensor, given it an Italian tune up and eventually cleaned the EGR out in July of this year. The EGR was caked up and this had seemed to stop the issue, however now it's back again.

The vehicle is mainly used for short journeys, less than 2 miles, 5 or 6 times a day, the engine temp guard says that it hits half way so it does warm up in this time.

I'm guessing that the short journeys is causing the issue and I'm going to have to remove the EGR to clean again HOWEVER it strikes me as odd that this would be happening again unless there is something else which is a problem. The CEM failed a month ago which we replaced with a referb unit but other than that, the only issues we have had are mechanical wear and tear.

When it kicks into limp mode we have to turn the engine off, put it in park, floor it to 4500 rpm which blows a whole pile of black smoke out of the exhaust and it leaves a soot mark on the floor. We do this a couple of times and then the exhaust gasses are the usual colour. Restart the engine and all is good for a while.

Any ideas on what could be causing the issue?

The other thing to bare in mind is that the exhaust stinks, not like the usual Diesel, more....dirty I guess.

[gmonag]

You really should stop guessing and read the DTCs. That will give you some idea.

However, my GUESS is that the turbo is shot. Probably leaking oil, causing smoke, gumming up the EGR and most importantly coking up the Inlet Guide Vanes in the turbo.

Find the cause of the limp modes. In this case I would expect an Overboost code or MAP faulty flow.