Hi Tulmaster, i would like to help someone in return as this is a problem that caused pain and misery for me for months and months on end with my alfa romeo diesel.

My symptoms were the same as yours, in cold weather especially the car wont throw the error and limp, but when it gets hotter and you give it some load the bam, limp mode.

I have replaced so many thing on my car...

-Fuel lift pump
-High pressure pump seals
-Fuel regulation valve
-Fuel pressure sensor
-MAP sensor
-MAF sensor
-vacuum pipes

But the fault at the end of the day was the injectors, the valves inside were buggered and as a result the leak back is too much and the pressure drops too much in the rail.

A leak back test revealed the 2 faulty injectors and so i got them reconditioned and viola the fault never came back.

Just for reference, if your car has difficulty starting its more likely to be the high pressure pump at fault but if it starts fine but just hits limp mode when warmer and under load then i can almost guarantee you its the injectors, have them checked and let me know what happened ok? cheers

 

Okay just an update. I finally took the crd to a dealer. Luckily they have a flat rate for diagnostics as I was there for 8.5 hours while they worked on it without finding the cause of the problem. They confirmed a few things though, ECM and wiring are not the cause and they check several things that I already had done, cac hoses, flow to EGR etc.. All said and done the gave a save face suggestions of flushing the intercooler due to a slight pressure difference between the two sides and of course, replacing the aftermarket fuel filter head with stock. Seems they felt that my pressure gauge on the filter head (which measures the aftermarket electric lift pump fuel pressure) dropping to 2psi under load might be an indication of lack of fuel delivery. I didn't have the heart to tell them it would have to show a neg 10 before it would indicate a problem. The did verify that the fuel pressure in the rail was okay at all conditions except under very heavy load and then only slightly low. P0093 sets only at slow cruising speeds and then goes into limp mode.

So a couple questions I have for those out there. How many different things actually cause limp mode? Like will it be set by bad turbo pressures? or will a bad boost pressure (Map) sensor cause a limp mode. When is the Map sensor considered bad if it tests operational?

I did remove the intercooler and flushed it with a degreaser as best as I could. Sloshed it back and forth, let it set then sloshed it more. Then flushed with soapy water repeatedly until clear water. Originally I had poured about 2 oz of oil from the insides. I reinstalled and problem stays the same.

Can anyone confirm that the 05 CRD does or does not have and oxygen sensor? thanks