Is towing a caravan causing a fault with my Mondeo TDCI's turbocharger?

Three years ago I bought a Mondeo 2.0TDCI, good condition, full service history, 39,000 miles (now 48,000) to tow my caravan, which it has done very well. Three weeks ago while driving solo the turbo cut out and went into limp home mode, I took it to my garage and was told it needed a new turbo. This was fitted, but when I started to drive it again it had flat spots and low power and lots of black smoke until the turbo kicked in. I took it back and was told there were no faults showing and it needed a good run, I did this solo and with caravan hitched, but no improvement.

I also noticed reduced fuel economy so I took it to another garage for a second opinion, they said no faults were showing, but they cleaned the EGR and still no improvement. With further checks they found engine rattles and something to do with oil levels. I can't remember exactly what they meant, but they think all this could lead to injector problems and advised injector testing, then filters and mass airflow sensor. I am unsure which direction to take, and hope you can give me some advice please.

Asked on 15 June 2013 by RW, Leeds

Answered by Honest John
The worst thing you can do with a turbodiesel is to tow a caravan and not idle the engine for two minutes every time you stop. The reason is that towing overheats the turbo and the airflow cannot cool it sufficiently. When you stop, engine oil circulating through the turbo bearing continues to cool it just enough. But if you switch off, the oil in the turbo bearing instantly carbonises and the turbo spools down with no lubrication. When you replace a turbo you also need to replace the oil feed pipe to the turbo because the oil in that could also have carbonised, restricting the flow to the turbo bearing, and I think that is what has happened in your case.
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