I have a Stilo Multiwagon JTD 115, on the road yesterday I gunned it to overtake a slower car, mid overtake there was a great plume of smoke from the back (grey smoke), engine light came on, engine ran on for about 10 seconds then returned to normal. Car seems to drive fine but..... I appear to have oil leaking from the intercooler and there is a great plume of smoke when I start up.
Thought it was the turbo but as the car seems to be driving fine I dont think thats it.
any thoughts would be appreciated.

HMMMMMMMM.....so many possibilities!!


OK, first off, is the MIL still on? my first thought is simply MAF or EGR.


A blocked EGR will definitely give out plumes of smoke on kick down, but usually you get a drop in power too or at least a delay - did you experience that?


A faulty MAF will cause power issue, often smoke can be a symptom, so worth checking the maf although if the MIL is on then id get a code reader first.


as for the oil leaking from the intercooler...where, form the IC itself, or associated pipework? Id personally get it up in the air, remove the inner wheel arch and plastic coverings and check all the pipe work etc. No reason to think its a blown turbo yet, but you may well need to clean up the pipe work,. oil catch tanks etc and probably the air filter i expect (probably covered in oil).


You have some work ahead of you, but its simple stuff.


Oh, check the MAP sensor too, its next to the EGR so I'd blank the egr or fix it if broken, replace the MAP, check and replace the MAF, new air filter, check I/C and pipe work and tighten all connectors and clean...

Thanks for that. The MIL is still on. Will run through your suggestions. Definately think the EGR is a goner; going with the symptoms described on the forum, the rest I will work thro and post back on results.

I had a very similar thing and found the small pipe going to the solenoid valve which I think controls the turbo boost had come off. Very loose black sleeve fit to valve. Made new connection and all fine now....

took off the intercooler and emptied out some oil, removed all the pipework and cleaned it all out. Changed the air filter. Put it all back together and bingo! MIL was out, everything was running fine and smoke free.
There was a small hole in the intercooler, will this have much of an effect on the boost? obviously will be leaking pressure.
Will be tackling the EGR next, will just blank it off.


Thanks for the help

Yep - performance/ boost pressure will be down. Depends upon size and position could fix with sealant ( 2 PACK TYPE ) that will go solid.

yup as above, it needs to be a sealed unit, so any pin holes etc will have an affect. As said, you can try a repair if its a small hole using some liquid weld, the two pack type that you mix together. I did this on my 4x4's intercooler and its been fine since - no leaks.


glad everything has worked out, and yup, get the EGR blanked off properly and enjoy the benefits. Had mine done for years now and the emissions are actually better so there's no real world argument for not blanking it as far as I am concerned!