Ford Mondeo - Mondeo 2006 TDCI - over fueling?

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Fri 6 Mar 2015 18:40
Ford Mondeo - Mondeo 2006 TDCI - over fueling? - rk505

Hello all,

Would welcome any analysis or advice on the problem i am having with my Ford Mondeo.

I bought recently, with 95,000 on the clock, and it has had some faults:

- Engine was hesitating, and blowing white, then black smoke

- EML indicated a faulty EGR valve. EGR valve was seriously chocked with carbon, it was almost fully closed.

- I replaced the EGR valve, new intercooler hose.

This stopped the hestitation, and MPG has slowly increased to 41MPG.

However, upon accelation on load, it still smokes. Mainly grey / black smoke.

I noticed a slight hunting one day, and had a dianogstics test done. It indicated that the indicators are ok.

I had fuel filter replaced, since i have had no hunting.

Can be a struggle to start, keep the ignition held for 5 - 10 seconds, then the engine fires up. It takes a further 10 seconds for the engine to fully start, then dislplay lights disappear, and i can actually drive it. Usually get white smoke upon starting. And again, on acceleration i get the over-fueling. Over fueling isnt consistent though.

Normally when the engine is warm, it drives really well.

I have spent money on service and repairs, and would welcome any advice on the over fueling and starting issues.

Many thanks

rk505

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Fri 6 Mar 2015 20:33
Ford Mondeo - Mondeo 2006 TDCI - over fueling? - chris.o
The fuel Injectors can be an issue on the TDCI Mondeo.
They can be difficult to diagnose whilst still in the vehicle. It is possible to recode the injectors whilst they are still fitted. You need a reasonable piece of diagnostic kit to do this.
My advice would be. Find a decent diesel specialist, get the injectors recoded, see if this helps. If not get them removed and tested. Unfortunately if one or more need replacing, it will become expensive.

Chris
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Fri 6 Mar 2015 21:41
Ford Mondeo - Mondeo 2006 TDCI - over fueling? - Railroad.
If the EGR valve was clogged with carbon as badly as you say then so will the rest of the air intake system be downstream of it. Perhaps you should remove the intake manifold and give it a serious clean. I'd soak it for a minimum of 24 hours in a bucket of a 50/50 mix of heavy duty traffic film remover and water.

The fuel injectors will not have just lost the coding, unless someone has been playing around. That doesn't mean they can't be worn though. Modern fuel injectors are very precise, and common rail diesels have at least three injection phases for normal running. They have a pre, a main, and a post injection phase, and an after phase for DPF regeneration if fitted. These phases mean the injector has to be very carefully set up. Upon doing so the injector will be given a code which must be programmed into the ECM to tell it how to operate the injector. The engine will still run even if the injectors codes are not programmed into the ECM. It will just not run as well or as precise. If you have your injectors overhauled they will be given new codes.

Black smoke on a diesel means too much fuel or too little air. In that respect modern diesels are no different from their predecessors.
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Wed 8 Apr 2015 02:23
Ford Mondeo - Mondeo 2006 TDCI - over fueling? - rk505

Many thanks for your reply, i will look into cleaning the manifold.

Much appreciated.

Cheers

Rk505

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Wed 8 Apr 2015 10:40
Ford Mondeo - Mondeo 2006 TDCI - over fueling? - jc2

This calibration is designed to over-fuel on acceleration-will return to normal calibration on cruise.

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