There is a raft of info on this problem around the web. Mostly for 1.5 dCi or Laguna cars however any such topic seems to decay into various sub discussions and they don't exactly ever reach a conclusion. My car is a RS175 2.0 dCi. Last week I had a bit of a hoon on my way home. The next day I got a check injection light and the spanner came on. Lasted about five seconds, car dropped revs then seemed to clear. Normal service resumed. On Friday I gave the car some stick, up to the red line a few times. All was well. Wife took the car out yesterday and the check injection came on reportedly three times. She's got limited mechanical sympathy and understanding and became a panicking pregnant woman to the effect I had to get two trains and a lift to go and meet her and drive the car home. Car drove faultlessly and we covered the 40 miles on the motorway fine. Albeit I drove sensibly and didn't Rev the car out. What I noticed yesterday after a quick look before driving the car was that a few bubbles were present on the clear plastic fuel lines by the bulb and across the front of the engine. The car started and ran fine. I don't know if this is normal or not. Anyway I checked those hoses this morning and they were free from bubbles. Started the car and immediately got a check emissions light and the spanner plus a general MIL engine light. This doesn't go off and the car is limited to 3000 rpm although you can drive normally within that limit. I've inspected the hoses (air supply, feed, fuel lines inclusive under car), checked maf for gunk, checked all connectors, checked earths, checked DPF pre and post pressure sensor feed pipes. All appears well. Of course a lot of this stuff is barely accessible and I haven't been stripping the parts out and pressure testing them so they could indeed be faulty but it's not obvious if they are. I disconnected the battery negative lead in the hope it would clear the code(s) and let it sit for 20 minutes but that didn't work. So that either didn't clear the latched memory or whatever is causing the fault is being picked up on every start now. I'm looking into getting a fault reader. I took some pics of those fuel lines. Perhaps someone can say if the bubbles are normal or not?
On my old Laguna dci had the same problem and turned out to be the rubber primer letting air in, But I had difficulty starting when cold as well.
So, one week on and I've got a fault code. P0409. Seems it's a egr sensor A circuit. From what I've read this isn't necessarily egr related. I cleared it and drove the car for a day with no issues. Got on the cat to drive home at the end of the day and it appeared again. It only comes in on start up and latches on.
If it's registering a fault on start up it will be egr related as the egr is only functional when cold on tickover. Egr is most likely full of gunk
I've spotted that the EGR pressure solenoid valve seems to be missing a vacuum pipe at the front. Can you have a look at yours please and advise? It's the black cylindrical looking chap with a plug on the front of it and pipe work at the rear. Mine has a stub at the front which you would assume connects to a pipe (unless it's measuring atmospheric at this point). It's located on the right hand side of the head, just below where the engine cover clip pops through the metal retainer.
