Ford Mondeo III (2000 - 2007) - 04 2.0 130 tdci - misfire/hesitation....turbo?  
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306
My 80,000 miles mondeo hatchback has developed a fault! (surprise)

I noticed am occasional missfire/hesitation on accelerating, and a noise not unlike a loud fan at about 3000 rpm, not the normal turbo whine (which I know quite well), more a spin drier full of sand)

on cruise, at 65, on the level, nothing untoward, hit a hill and the misfire (very slight) is there with an occasional puff of black smoke, on hard acceleration im getting too much black smoke now. (even for a tdci ford.......)

its the woooshing noise thats just appeared that makes me think its the turbo, at first i thougt "split exhaust" - it only comes in on acceleration and at about 3000 rpm+

didnt need this with dad admitted to hospital 30 miles away.....

any thoughts?

Edited by Dynamic Dave on 30/05/2008 at 18:36

Tags: technical issues turbochargers unexplained noises 4x4s

04 2.0 2004 130 tdci mondeo.....turbo? - nottsruss
Dont wish to alarm you but this recently happened to me , same symptons etc and could not diagnose . The car ran for a while as this as i do very high mileage 70 k year happened at 145 k . In the end i completely lost power , a turbo impeller shaft bearing collasped and impeller shaft sheared , the turbo is mounted on inlet manifold so not a simple job.
Remove inlet duct to turbo and spin impeller with finger , listen for any noises or hard to rotate or play in impeller. Hope this helps.
04 2.0 2004 130 tdci mondeo.....turbo? - mondeo1306
sounds like it to me

i can avoid noise+smoke JUST by driving very careful and under 2000 rpm

how much was the turbo supply+fit+vat?

04 2.0 2004 130 tdci mondeo.....turbo? - nottsruss
Cost me £520 fitted trade , but heard can cost £1000 at main dealer !!!
04 2.0 2004 130 tdci mondeo.....turbo? - mondeo1306
been quoted £340 for a recon plus vat plus fitting

two types, vacuum or electronic actuator

not sure which i have

they are waiting for software before they can do a recon electronic actuated type, £660 new for now, £340 when they can do one recon

Edited by mondeo1306 on 30/05/2008 at 13:20

04 2.0 2004 130 tdci mondeo.....turbo? - Screwloose
1306

Far more likely to be a boost pressure leak. Split hose, loose clip, split intercooler, etc.

If a REA electronic turbo fails, you'll usually get code P132a come up.
04 2.0 2004 130 tdci mondeo.....turbo? - mondeo1306
turbo has a vaccum advance thingy on top of it (like my viva distributor used to have) so im assuming its a vacuum version, its deffo a garret
04 2.0 2004 130 tdci mondeo.....turbo? - mondeo1306

i took the convoluted flexipipe off the turbo intake, the vanes looked ok, the shaft didnt seem loose, there was some oil sitting on the bottom of the turbo pipe/casting intake
04 2.0 2004 130 tdci mondeo.....turbo? - Screwloose

Turbos are always a bit oily; look for the trademark oil-mist stains that betray a boost leak.
04 2.0 2004 130 tdci mondeo.....turbo? - mondeo1306
cant see not a glimpse of anything untoward, at least not from above the engine, it all looks ok, with the turbo intake off the noise did seem louder, not in a intake roar kinda way, more like a bag of nails spinning round

having said that, with the pipe on it sounds quite normal if revved up but not driven...

Edited by mondeo1306 on 30/05/2008 at 18:01

04 2.0 2004 130 tdci mondeo.....turbo? - paulontour
That bag of nails spinning around is probably your crank pulley failing. It drives your auxillary belt.
04 2.0 2004 130 tdci mondeo.....turbo? - mondeo1306
That bag of nails spinning around is probably your crank pulley failing. It drives your
auxillary belt.


that wouldnt give extra smoke+the hesitattion though would it...
04 2.0 2004 130 tdci mondeo.....turbo? - paulontour
No of course not, that is only a possible answer to the bag of nail sound. The black smoke and hesitation is probably due to a split intercooler hose. I experienced both these problems on my tdci. I found the split pipe and replaced it, that cured the hesitation and black smoke. Once my pulley was removed it almost fell apart in my hands, that cured the bag of nail sounds
04 2.0 130 tdci - misfire/hesitation....turbo? - paulontour
Nothing more than a split intercooler hose.
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306
Nothing more than a split intercooler hose.


possibility i suppose................
04 2.0 130 tdci - misfire/hesitation....turbo? - Pugugly
Let us know ! This could be a reference thread !
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306

maybe it does sound like compressed air being force out, then again you mind can play tricks on you, cos that would probably be cheaper to fix!

where is this pipe, under the ally heat shield on the exhaust side of the turbo?
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306

the noise/hestitation/hiccup is load+throttle related, revving the engine up at standstill gives no noise or smoke, driving steady isnt a problem

its coming under load (hill) or harsh acceleration where the problem comes in, once 2500 rpm is hit, which means to me it must be turbo-related.

04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306
cursory examination has revealed nothing, i squeezed a few rubber sections joining metal pipes (2" dia) - one had bands of wires round it, is that boost or aircon, damned if i know

theres no oil mist anywhere, no drips, no leaks

revved up at standstill looks/sounds perfect...

crank pulley feels ok too....
04 2.0 130 tdci - misfire/hesitation....turbo? - paulontour
As you look at the engine the pipe is situated between the engine and intercooler. The intercooler is a secondary radiator that cools the air and is located behind the water radiator. In appearance the intercooler hose looks the same as a water hose and is easy to get the two mixed up by just looking at them. It runs from the top left hand side of the engine to the bottom left side of the intercooler. Look for a damp spot on your hose and surround and also watch for a fine mist. The intercooler is a high pressure system and if you pipe is split the turbo will not function at full boost. The split will open and close very quickly and it is this that gives the impression of an engine missfire or hesitation.
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306

Looks like a trip to Ford between hospital trips
04 2.0 130 tdci - misfire/hesitation....turbo? - paulontour
I still say this is nothing more than a split hose. It took me the best part of a week to find it, and it was right there under my nose. Keep looking there are more flexi pipe around the back and under the engine.
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306

my under car days are over, ill have to ring the sick bay....
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306
looks like its a split hose, found the tell tale residue right under the EGR, on a bend in the 2" pipe running straight down

ford say it should be p/n 1122510 bout £20 plus vat, can i go to look at his screen....but no stock


wheres my gaffer tape...................
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306
6 feet of duct tape and 4 cable ties sorted it till ford get me one
04 2.0 130 tdci - misfire/hesitation....turbo? - paulontour
glad I was able to help.
Paul
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306
glad I was able to help.
Paul


thanks a lot, cheaper than a new turbo, thats for sure!

after a run and some STP injector cleaner (and a quick clean of the EGR valve) its back to its old rip-snorting ways, when i locate the fuel filter ill give it a service, i found the oil filter while i was underneath the sump....
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306

part number PF 1222831 £25.10 plus vat

at least dick turpin had the decency to wear a mask
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306

seems besides the regular problem of this hose splitting, the EGR valve and MAF sensor can both cause problems, i have pulled of and plugged the vacuum pipe tp the EGR (which i have cleaned out and the car is running almost smoke free, and certainly without the big plume of black smoke it had before

i shall also be cleaning the MAF sensor

04 2.0 130 tdci - misfire/hesitation....turbo? - Screwloose
i shall also be cleaning the MAF sensor


Best way to ruin it.
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306
only with some contact cleaner from maplins, not a wire brush

04 2.0 130 tdci - misfire/hesitation....turbo? - Screwloose

Contact cleaner will finish it; it must be a totally residue-free solvent and preferably don't clean it at all - if it ain't broke etc....
04 2.0 130 tdci - misfire/hesitation....turbo? - mondeo1306
shall investigate the state of the intake manifold then, which seems to be another culprit, with large build ups of gunge just like the EGR gets.
04 2.0 130 tdci - misfire/hesitation....turbo? - delta-box
Hi All,

I have a very similar problem on my focus tdci 04 115. Under load it sounds like the exaust is blowing with a whiring sound, that and the engine is a bit rattley? When I depress the clutch the rattling stops.

I will check the turbo pipes the weekend but any advice would be gratefully recieved.
04 2.0 130 tdci - misfire/hesitation....turbo? - spikeyhead {p}
If there's soot on the underside of the engine cover it's a sure sign of a split pipe.
04 2.0 130 tdci - misfire/hesitation....turbo? - splithose
I have the same noise problem, rattle goes away when clutch depressed, if clutch pedal pressed slowly it tries to push jerkily back. this is on a Mondeo 130 tdci 52 reg,
141k . I thought the turbo had gone but traced it to a split hose. Noise still there though. I thought maybe the thrust bearing or clutch as they are origional items.
04 2.0 130 tdci - misfire/hesitation....turbo? - deputyone

thanks for the very usefull information . had the same symptoms on my 54 tdci 130 mondeo. missfiring and whooshing noise on acceleration, checked it out on this advice site . found problem straight away .Big shock when ordering new hose from ford dealer. £48.75 !!!!!! daylight robbery ..

04 2.0 130 tdci - misfire/hesitation....turbo? - thistletrader

I had the same symptoms - temporary loss of power and puffs of black smoke etc., so I took Paulontour's advice and found a split on the bend of the intercooler hose which I have sealed with super glue and loads of duct tape and everything is now fine.

Many thanks to Paul - you are the man...............

04 2.0 130 tdci - misfire/hesitation....turbo? - DeDentist
I have just had this whooshing noise appear on my mondeo, missfires and hesitation at 2k revs.. and that turned out to be the O/S hose on the intercooler.

The split is so small for such a loud noise, the good thing is it does leave a residue
mark near the hose... thank goodness for forums :)

Edited by Dynamic Dave on 24/08/2009 at 12:32

04 2.0 130 tdci - misfire/hesitation....turbo? - samboy
turbo salutions in darlington turbo with electronic actuator 500+vat
04 2.0 130 tdci - misfire/hesitation....turbo? - Midnight Geoff

Just got my car back from my local Ford garage, it had the same symptom as yours. It cost me £125.00 for them to replace the intercooler pipe. I wish I had found this site earlier. It would have saved me some money.

04 2.0 130 tdci - misfire/hesitation....turbo? - jcallaghan
Hi, i have a 55 plate 2.0l diesel, when you push the accelerator you can hear a sound like the fan on full blast? Every now and again you feel a slight judder but only for a second or two - this is intermittent..... can anyone shed any light on this please???

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