So I searched my workshop manual and the internet to try and find a fix for the problem. I quickly determined that the cause was likely a blocked gauze filter on the EGR Cooler. One mechanic had posted that a failed DPF (Diesel Particulate Filter) could also be the cause and a check of the exhaust pipe where sooty deposits may be seen and a rattle on the DPF would occur when shaken. Mine proved OK, the exhaust pipe was perfectly clean and the DPF located at the LH rear of the engine as viewed from the front of the car seemed fine when shaken.
My workshop manual does not cover Ingenium Engine repairs so again I looked on the internet for more clues but it was quite confusing as some repairs related to Land Rover vehicles where the engine is mounted transversely. There was one you-tube video showing the filter replacement and rebuild but it was difficult to make out what was happening and the accompanying music did not fit my taste.
I ordered a new filter and while waiting a couple of days for delivery continued to research how to fit it. One good point was that the filter and gasket cost only £17 with the delivery on top.
I stared work as soon as the filter was delivered and surprisingly the job turned out to be quite easy and did not take too long. I estimate that an experienced mechanic would have it done in 1 hour.
For those who service their own vehicles from either necessity or are just hobbyists, here is a step by step guide.
2.Remove the plastic Air Duct between the Air Filter box and the Turbo Inlet casting. (There is 13mm headed bolt in the middle, a Jubilee clip with 7mm head at the Air Filter box end and a wrap around hose clamp at the Turbo end).
4. Disconnect the rubber breather hose that links the top of the Turbo inlet to the Camshaft cover. (Two 8mm headed bolts at the Turbo Inlet and a retractable collar at the Camshaft cover). Wiggle the hose free as it has a large O ring engagement flange.
5. Remove the Turbo inlet casting. (Undo the two 10mm headed screws on the top, the harness plug to the electronic module on the LH side and separate the cable harness holder and lift the casting away, again there is a O ring engagement flange to wiggle free).
7. Clean the mating surface of the EGR Cooler and vacuum it out to ensure any debris is removed.
Reassembly is simply the reverse process but be very careful when tightening the screws and bolts as it will be easy to strip the threads in the aluminium components. I could not find torque specifications for the bolts and screws but would expect the six T30 torq screws to be about 8NM and considerably less for the T15 screw.
The fault code did not need deleting as the engine light did not illuminate when I started the engine and a test drive was successful.
In the end it was quite and easy job to do, and one that will no doubt crop up as these cars cover similar mileages.
Mike.