2008 Ford Mondeo 2.0 TDCi Intermittent P2263 Fault

[faz786]

Hey Guys, 

I am new to this forum so thanks for having me. 

Iv searched for a few days and struggled to find a thread describing the same fault as mine. I understand may have had the P2263 fault but mine is intermittent. 

My car drives well however, occasionally when driving on the motorway with slight throttle applied, the car will judder (like an on and off surge) and then will go in to limp mode with EML illuminated. Scan the car and code is P2263. When you turn the car on and off again, the fault will go. I did a rough check on the vacuum pipes with brake cleaner (not the best way but does work) and found no leaks. Had a brief look and the turbo/intercooler pipes and couldn't find any splits or tears (although I have to say, it was a brief look). I also checked the movement of the actuator arm and it moves freely. 

I do feel like the car has some sort of air leak as I can hear the turbo whistling (kind of like a police siren) and it takes a few seconds longer to start when cold. 

The reason I am a little stumped is because if there was some sort of torn intercooler pipe, wouldn't the car be in limp mode all the time and not intermittently?

Also, the solenoids do not make any of the "mooing" sounds to suggest that they are faulty. 

The car does 100 motorway miles a day. 

Could anybody help shed any light? 

Thank you in advance. 

[Shab99]

I have a similar problem and I think I have finally worked it out after many years. Does the problem happen when you are going about 70mph with the revs at about 2k? Does it also happen when you are accelerating hard up a hill?

If so, next time it happens try this: Put your foot on the clutch until the revs drop to zero. Rev the engine hard then let it drop down. Repeat a few times. Then drive normally and see if your turbo is back on - you might still have an EML but you will know the torbo is working from the power.

Secondly, try this: Disconnect the electrical connection to your EGR. This wiill cause an EML but the car should drive normally. See if the problem happens again.

If either of these responses work it suggests your EGR is the source of the problem as it is not opening/closing properly, probably because it is full of gunk. Try cleaning it.