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Mondeo 2 Ltr TDCI Injector Problems  
Mondeo 2 Ltr TDCI Injector Problems - Pip
I have had this car from new at the end of January 2002. The car is used for courier work town and country.
After about 3000 mls the glow plug light started to flash, I took it back to my dealer and was told it was an injector fault. They adjusted the injector and it was OK for a few more 1000 miles. Then the same problem again, same procedure as above and it was OK again. You guessed it happened again, this time they renewed No.3 injector. All was fine till last week when it happened again, this time they are renewing No.4 injector.
Is anyone else having this problem, or do I have a bad car.
I have 23000 mls on this engine. The best mpg I have got from this car is 38 mpg.



This post has now reached 86 replies. A new Volume has been created since a poster asked for specific help. Just to make reading and responding a bit more managble -PU

Tags: technical issues glow plugs gearboxes finance

Mondeo 2 Ltr TDCI Injector Problems - Mr T J Smith
can't really comment on the injectors, which incidentally are a delphi item. I can however comment on your fuel consumption which given the experience i've had with mine seems daft, and suggestive of a problem. my car gets used predominently around town, with some long motorway hauls, and occasionally gets asked to lug a 9m trailer around. If i ever see less than 45mpg from it, it's a suprise, and on a motorway run cruising at errrm, 70mph ;-), 50+ mpg is a regular occurance.
Mondeo 2 Ltr TDCI Injector Problems - madf
Tell the garage in writing
1. It is not satisfactory:
2. the engine is cleary faulty
3. Will they replace it now or can you have a new car.

Whilst not reasonable it might get them to sort it: you obviously have more than an injector problem: sounds as if it is fuelling too rich or there is dirst in the tank fouling the injectors or an ECU problem.

As it is new, you should not be posting on a website asking for help: THEY should be fixing it.
madf
Mondeo 2 Ltr TDCI Injector Problems - Honestjohn
TJ Smith is the first to praise the fuel economy of the Mondeo TDCi in The Backroom or among my Telegraph readers.

HJ
Mondeo 2 Ltr TDCI Injector Problems - Julier
OK, I have exactly the same problem!

After ~3k miles, the warning light flashed, and I got a loss of power (as if the turbo had fallen off), I also get about 40 MPG. This was taken to my local garage, who diagnosed water in the fuel ? this looked like a load of bull at the time, never the less they were adamant. On Saturday the very same thing happened again (after 1k miles), this time the car was taken to a different garage who knew of the problem ? although they would not confirm what it is, they confirmed it was not ?Water in the fuel?.

So, if you have this problem, do search pages like this, and if your dealer is claiming that it?s ?Water in the fuel?, or any other excuse, ask ?Are you Liars, or fools?, since this is a known problem affecting a number of the 2.0 TDCi engines.

(I don't know if it is an injector problem - this may be just another excuse!)

I await mine being fixed.
Mondeo 2 Ltr TDCI Injector Problems - Flat in Fifth
Either of you guys got what seems like an occasional flatspot or misfire at around 1800/1900 rpm?

Two on our fleet have it, though mine doesn't appear to suffer. (yet touch wood)

Wondered if it was a mapping induced phenomenon?
Mondeo 2 Ltr TDCI Injector Problems - mondeoman
I have the problem you mention, which at first felt like a rev limiter at 2000 rpm. Ford have had the car twice now and it is better(install of latest engine management prog and injectors reprogrammed!)but fuel consumption has increased 5/10 %
Mondeo 2 Ltr TDCI Injector Problems - rivet man
Either of you guys got what seems like an occasional flatspot
or misfire at around 1800/1900 rpm?


Hi, I've got the same flatspot at 1800/2000 as you advised 3 yrs ago.

Was it ever cured? What was the cure?

Many thanks.

Rivet Man
Mondeo 2 Ltr TDCI Injector Problems - injection doc
flat in fith! Try getting your dealer to recode the injectors, this is a very common problem & for some unknown reason they loose there coding causing a lumpiness or semi misfire often at 1250/1750 &2250rpm more noticeable when cold. If you hold it at 1250rpm cold & its very lumpy they need recoding! I have had this numerous times & fuel economy vastly improves. Mine used to drop to 38av & 46+ afterwards
Mondeo 2 Ltr TDCI Injector Problems - Dynamic Dave
flat in fith!


Hopefully by now he's got it sorted as the posting date of that question was 18 Nov 2002 !

DD.
Mondeo 2 Ltr TDCI Injector Problems - algy
I would normally bow to your superior knowledge and wisdom HJ, but I have posted here before about TDCI fuel economy. For the record, however, my brim-to-brim figures for my '53 Zetec 130 Estate over 40K miles have produced 52mpg at best and 49 at worst, and 30-32 with a ton and a quarter of caravan on the back. So I am happy to endorse what TJ Smith has said. And I've found it a great car all round. My only criticism is the poor quality radio, which needs regular prodding to do what it should on RDS. I'm hoping to get hold of another low mileage example before the new model arrives - does anyone know when the new one is due out?
Mondeo 2 Ltr TDCI Injector Problems - sedpig
I have had my new Ford Mondeo TDCI estate since July 2002 (4K miles). Already it has been towed into a Ford dealer by the RAC twice. Both occasions, on starting, the glow-plug light would flash, the engine would turn over but it would not start. On the first occasion it was in the dealers for 7 days.
Eventually they changed the ICU (Injection control Unit).
On the second occasion (1 month later) the same starting problem occurred. This time they changed the CMP sensor, again something to do with the injection system.
Fords Customer services say, “If the car is towed in three times with an identical fault, we will replace the car.”
What they mean by “an identical fault?”
I feel I’m going to have more starting problems. Does anyone know where I will stand if I do?
Mondeo 2 Ltr TDCI Injector Problems - kurnal
For so many months I too thought I was alone in problems with my mondeo TDCI. I first took delivery in May this year and by July the engine was using a lot of fuel and smoking heavily, and some misfiring. Main dealer said no cause for concern. Then 3 days later, towing my caravan on the M5 at 3000 miles from new suffered severe power losses and glow plug light started flashing. Limped to a Ford dealer, car able to maintain about 20 mph on the flat. My BRILLIANT leasing firms tech department got to the bottom of it for me- Ford issued a confidential service bulletin on the problem on 17 July. The problem is in the diesel pump which has a manufacturing defect. the cams and rollers are case hardened but a number of pumps have a problem whereby the case hardening fractures and contaminates the whole fuel system with small chards of hardened steel. Total replacement of fuel system and flushing of tank is the only cure. Car off road about 4 weeks whilst spares sourced. Ask main dealer to check for fuel contamination- this will show up the problem. Thats what the flashing glowplug indicates. My car was fixed and off the road for a month, stranded 300 miles from home but Ford did look after me and paid the AA to bring the van home. On its return the car ran ok but had a misfire or flat spot at between 1800 and 2000 rpm that nobody could ever bottom. Then just 6 weeks later the fuel pump failure occurred again- at 6000 miles- off the road for another month. Ford finally replaced the car for me in November with a brand new identical model. However from the outset this one has had a flat spot/ misfire which occurs only with a warm engine between 1800-2000 rpm, on partial throttle settings. Its also only averaging 40 mpg on reasonably long runs-the other when ok was good for 46. I would love to get to the bottom of this although I havn't reported it to the dealer cos I know from last time they havn't got any answers for it.I know some but not all cars have this problem - one of the hire cars I drove did exhibit this symptom and a couple did not. The ones that ran cleanly though seemed also to be more economical. I have a feeling that this problem could be down to a software update that was made in August. Does anybody have a way into Fords technical department so I can get to speak to someone there who really knows their stuff rather than a call centre?
Sorry for baring my soul at such length but I have left loads of history and breakdowns out! - I would love to hear from anyone who has had similar problems. Still rate the car though!!!
Mondeo 2 Ltr TDCI Injector Problems - Flat in Fifth
"The problem is in the diesel pump which has a manufacturing defect. the cams and rollers are case hardened but a number of pumps have a problem whereby the case hardening fractures and contaminates the whole fuel system with small chards of hardened steel."

well well well well, some companies NEVER learn.

Middle Man; remember that off site discussion about Ford camshafts, quite some time ago now?


Mondeo 2 Ltr TDCI Injector Problems - Dizzy {P}
FiF,

I also remember the problem well -- if you mean where Ford were letting camshafts with soft cams into their system and 'lack of servicing' was blamed for the subsequent wear. Long while ago though - back in the 70s I think?
Mondeo 2 Ltr TDCI Injector Problems - Flat in Fifth
Dizzy,

that was just one of the problems, they have had a few problems more fundamental than that but all in related areas I would say.

In the 70's you are correct. I was aware that the problem still existed on old designs, eg Ka engine. Didn't until now realise that the metallurgy still leaves something to be desired even on new designs.

Better leave it there I'm afraid, don't want to get into trouble.

Cheers,
FiF
Mondeo 2 Ltr TDCI Injector Problems - Roly93
FiF,
I also remember the problem well -- if you mean where
Ford were letting camshafts with soft cams into their system and
'lack of servicing' was blamed for the subsequent wear. Long while
ago though - back in the 70s I think?

I remember this, I think it was on the 1.6 and 2.0 OHC cam or Pinto engines as they were known. Ive seen so many cortinas and capris with that awesome banging from the top-end due to this problem.
Mondeo 2 Ltr TDCI Injector Problems - kithmo
>> FiF,
>>
>> I also remember the problem well -- if you mean
where
>> Ford were letting camshafts with soft cams into their system
and
>> 'lack of servicing' was blamed for the subsequent wear. Long
while
>> ago though - back in the 70s I think?
>>
I remember this, I think it was on the 1.6 and
2.0 OHC cam or Pinto engines as they were known. Ive
seen so many cortinas and capris with that awesome banging from
the top-end due to this problem.

It WAS lack of servicing that caused cam failure on the Pinto engine, there wer no "soft" Ford camshafts only the cheap aftermarket ones that weren't heat treated correctly. The problem was that the camshaft oil feed pipe used to block up with gunge if the oil and filter wasn't changed frequently.
Mondeo 2 Ltr TDCI Injector Problems - Micky
Wasn't it a lubrication problem? Blocked oilways? Pinto was/is a lump of pig iron which could run for ever and a day when the problems were fixed. Still a lump of an engine though.
Mondeo 2 Ltr TDCI Injector Problems - cheddar
My dad had a 74 2000E that had camshaft wear probs at 12,000 miles, it went on to do over 100k without further probs.

He also had a 83 Pinto 2.0 Sierra that did over 100k in three years, and 86 and 88 Pinto Granadas the last of which was only changed last year at 200k miles.
Mondeo 2 Ltr TDCI Injector Problems - DP
The Pinto's problem was due to the way the cam lobes were lubricated. A "spray bar" ran along the top of the camshaft with a small drilling above each cam lobe. Oil flowed from these drillings directly onto the cam lobes. If oil changes were neglected, these tiny drillings would block with solidifed oil and the lobes would be starved of oil.

Changing the oil at the recommended intervals (or a couple of k less) would ensure this never occurred. My old 1600 Sierra did well over 200k on its original cam and the lobes were still in fine fettle. The car had never skipped a service in its life.
Mondeo 2 Ltr TDCI Injector Problems - ade
I have a January 2002 TDCI it is used as a taxi I puchased the car from ford direct at the end of Sep 2002 since then i have done 20000 miles in it. I now have it in the local ford dealer who are saying I have contaminated the fuel and they will have to change the whole fuel system. It is good to read other pepole are having the same problem (not good that this is happening).
I would like to know how anyone else has got on and if they have had any joy from ford.

P.S. still waiting for car to be fixed!!!!!!!!
Mondeo 2 Ltr TDCI Injector Problems - Kevin Moorey
I have a 2ltr TDCI mondeo. I have had not problems until now. I have done 20,000 miles. Problem started with loss of power and a lot of smoke when excelerating. I took it to the dealership who kept it all day and then told me it was fixed.(engine management system re booted) It wasn't Took it back to the dealership who kept the car for some weeks and replaced the fuel pum, told me it was fixed. It wasn't. My vehicle is on its way back to them for the fourth time havin had "management problems" 2fuel pump problems" "injectors seals replaced" all to no avail. I now have flat spots between 1800 and 2000 rpm, excessive fuel consumption (down to 34mpg from 41 arround town) smoking, stalling and restricted power in top gear. Ford have been useless in that the were not keeping me informed, fixing the problem and long delays in sourcing spare parts. Up until now I have been very happy with my car and now I would not buy another ford if my life depended on it.
Mondeo 2 Ltr TDCI Injector Problems - Kenneth
I had my Ghia TDCI in June 2002(new).All was well until November 02 when I experienced loss pf power. Swarf in the fuel was diagnosed. Ford replaced the pump,injectors,common rail and all pipework.Three weeks off road waiting for parts.April 02 came and loss of power occured again. New injectors fitted plus new instrument cluster( faulty low fuel warning light).1 week off road. On both occasions hire/courtesy car provided.11 th July 02, loss of power again. Injectors recalibrated,one day off road.I asked why calibration was necessary- "could have been a numbers of things" was the answer!The car has done 26000 miles now and when running OK is excellent, but I do not need this as I am self employed. I have written to Fords Customer relations at Glasgow and am awaiting a reply. I had a Bromleys Tunit module fitted but I am assured that this is not the problem,although I take it out when a visit to the garage is required!
Mondeo 2 Ltr TDCI Injector Problems - alex137
I seem to be having the same problem with my Mondeo mark2 TDCI. The car was registered in Sept 2002.
The glow plug came on and started to run slowly. I took it to a Ford Garage to ask them to look & repair. They said it was an Injector and would cost around £380 to repair. So I asked them to complete this and all was fine, until I double checked the work and found the oil seal around the injector was leaking. So it went in again and their repaired this surprise surprise FOC.
I drive the car approx 15miles and after this it failed to start again.
I asked the AA to check this. They looked and I agreed that it looks like the engine is being staved of fuel and is likely to be the fuel pump.
So went in garage again. They looked into this and have comfirmed that the fuel pump needs to be replaced and did this. I chased on progress and found that they could still not start the car and think that two further injectors will need to be replaced due to some metal particlars being found. They also keep going on about wiring diagrams from Ford, which you would think they would have considering the vehicle is three + years old.
They have changed the two fuel injectors and still can't get the car started. They are saying that Ford advise that if there are metal bits in the fuel the whole fuel system needs to be replaced. They have mentioned that if petrol had been in the system the fuel pump would lose lubrication. I know for a fact that the car has not been filled with petrol, so it must be to do with the cams & rollers.
I am real concerned that 1 they will never get the vehicle started and 2 do they know what they are doing.

I have a mechnical background and have some knowledge, so they can't pull some of the wool over my eyes, but I am wondering if they are igoring the fact of the bullets you mention and as they say it is out of warrenty and that I should pay for the whole system to be replaced (Which is not worth it) especially as they can't gurrantee that the car starting after this.

I would if you can suggest anything as I am running out of options.

Thanks!
Mondeo 2 Ltr TDCI Injector Problems - jkb080553
I have a 2 ltr TDCI Mondeo which suffered an injection pump failure, almost immediately after the glow plug started flashing, resulting in contamination of the fuel system and damage to the injectors. The car is only just out of warranty. I would be interested to obtain a copy of the confidential TSB you mention. When I reported a "flat spot" at low revs under load, whilst the car was still under warranty, the garage updated the software, which made no difference - the flat spot remained causing the engine to hunt when moving forward in slow traffic - only way to prevent this was to accelerate, declutch, or slip the clutch (something I hate doing for any length of time).

So far, no one seems prepared to admit there is a problem. I was impressed with the car until this happened - the flat spot seemed trivial at the time and I trusted the technical personnel.

regards

{unnecessary quoting of message being replied to removed - DD}
TDCI Injector Problems - mandy
I have a Focus TDCi Duratorq 1.8. which last week I spent £1,097 on repairs, following breakdown. A glow plug flashing light was the first indication of problems, followed by engine failure. car has 91,000 miles, year 02. I was most surprised when Ford informed me that the Fuel Pump required replacement. This is a major part and I expected it to last ,on a diesel, for the life of the car. Ford were keen to point out that the car is high milage for it's age. This in my opinion, should have no consequence, as the major parts are tested to go 'around the clock'. The car was leased, one owner before myself. I have only had it for 5 months. I have read the recall section on injector/fuel pump failure. Of course Ford insists this is not a recall problem. My car is now running ok. so i'm hoping all is solved. To all people who probably only look at these sites when in trouble like I did, i wanted to let you know that my car is now fixed. Ford replaced the fuel pump within a day, and did other repairs and maintenance for me at the same time. since then there has been no flashing glow plug light or engine cut out.
TDCI Injector Problems - Aprilia
Keep an eye on it. Fuel pump failure is often followed shortly after by injector problems (due to debris in the system). Just over £1k is not a bad price for this job...
TDCI Injector Problems - cheddar
I would hope that the dealer flushed the system.

Where Mandy is referring to Ford I assume they mean the Ford dealer, it is worth writing to Ford Customer Services on this, particularly if the car has full Ford service history.

There was a Ford TSB on this the text of which is as follows (note this refers to new injectors being fitted):

________

Model: Mondeo 2001 (Build Date: 10.2001 - 05.2002) (Build Code: 1K - 2J) (Engine: 2.0L DuraTorq-TDCi)
Focus 1999 (Build Date: 05.2001 - 05.2002) (Build Code: 1B - 2J) (Engine: 1.8L DuraTorq-TDCi)

Subject: Engine running erratically or does not start, due to contamination of fuel injection system caused by cam roller/shoe failure.

Summary

Should a customer express concern that the engine is running erratically or does not start, a potential cause (within the above mentioned manufacturing time period) is that the fuel pump is unable to deliver the required fuel rail pressure due to wear of the rollers and shoes. The damage is caused by insufficient bedding of the rollers during early life. This also creates metallic particles which can enter the high pressure fuel system and lead to injector failure. To rectify this concern, a revised fuel pump, new injectors and associated parts should be installed.

If this concern is present, it may be indicated by a flashing glow plug indicator showing that a fault has been detected.

Due to a number of misdiagnosed common rail fuel pumps, it is necessary to re-issue this bulletin. If any fault codes are present, these should first be investigated and resolved individually. If the concern is still present, a sample of fuel should be collected and analyzed to determine if insufficient bedding of the rollers has taken place.

________

TDCI Injector Problems - Pablo202
I'm new to this site and haven't ever been on one where I have made comment. Thought I'd let you know my little problem. I've had a Focus now from new (1999 on a T) company car for four years and bought it after that time. No problems. Best car I have ever had.....Sadly she wouldn't start the other day. Oh yes...she'll turn over but not start. I had a friend look at it and he said the fuel pressure wasn't enough and thought it maybe the fuel pump. A check with a computer on the old you know what confirmed it. Fuel pump. Was it worth doing? Well we hadn't had any previous problems and I had always loved the way it drove. So we had a quote from a Ford main dealer of about £1200.00. Not being overly happy with this I went private for £1000.00. Wife happy...Me happy. Until two days ago when the strut spring broke in half!!!!! But I've spent all day putting a new one on with my bother in law. Not much fun in the rain I can tell thy. Apart from being able to look at my shiny new fuel pump whilst the bonnet was up. Saying that I hope the injections are okay.....The pumps been done a few weeks now so fingers crossed eh.
When I rang Ford about the Fuel pump no-one mentioned that they had been a problem...but I guess they wouldn't. And no chance of getting my £1000.00 from them now.
Anyway...I love the car....it still goes really well.....smokes abit.....but it still goes really well.
All the best.
TDCI Injector Problems - Wales Forester
Pablo, assuming you have a diesel Focus it will be a TDDi on a 1999 T plate. Completely different powerplant from the TDCi unit.
TDCI Injector Problems - Pablo202
Yeap. I've had the car seven ish years and thought it was a TDCi. Well that just shows you how much I know about cars!! You proberly know best but I can't help it......I'm going to go out in the rain and check under the bonnet!!!!!
TDCI Injector Problems - Pablo202
Pete,
Well blow me down. TD Di. Cheers. Pablo.
TDCI Injector Problems - Wales Forester
Crikey Pablo, how far away do you have to park your car?! ;-)
Rest assured you're probably better off with the TDDi when it comes to repair costs.
Mondeo 2 Ltr TDCI Injector Problems - kurnal
For so many months I too thought I was alone in problems with my mondeo TDCI. I first took delivery in May this year and by July the engine was using a lot of fuel and smoking heavily, and some misfiring. Main dealer said no cause for concern. Then 3 days later, towing my caravan on the M5 at 3000 miles from new suffered severe power losses and glow plug light started flashing. Limped to a Ford dealer, car able to maintain about 20 mph on the flat. My BRILLIANT leasing firms tech department got to the bottom of it for me- Ford issued a confidential service bulletin on the problem on 17 July. The problem is in the diesel pump which has a manufacturing defect. the cams and rollers are case hardened but a number of pumps have a problem whereby the case hardening fractures and contaminates the whole fuel system with small chards of hardened steel. Total replacement of fuel system and flushing of tank is the only cure. Car off road about 4 weeks whilst spares sourced. Ask main dealer to check for fuel contamination- this will show up the problem. Thats what the flashing glowplug indicates. My car was fixed and off the road for a month, stranded 300 miles from home but Ford did look after me and paid the AA to bring the van home. On its return the car ran ok but had a misfire or flat spot at between 1800 and 2000 rpm that nobody could ever bottom. Then just 6 weeks later the fuel pump failure occurred again- at 6000 miles- off the road for another month. Ford finally replaced the car for me in November with a brand new identical model. However from the outset this one has had a flat spot/ misfire which occurs only with a warm engine between 1800-2000 rpm, on partial throttle settings. Its also only averaging 40 mpg on reasonably long runs-the other when ok was good for 46. I would love to get to the bottom of this although I havn't reported it to the dealer cos I know from last time they havn't got any answers for it.I know some but not all cars have this problem - one of the hire cars I drove did exhibit this symptom and a couple did not. The ones that ran cleanly though seemed also to be more economical. I have a feeling that this problem could be down to a software update that was made in August. Does anybody have a way into Fords technical department so I can get to speak to someone there who really knows their stuff rather than a call centre?
Sorry for baring my soul at such length but I have left loads of history and breakdowns out! - I would love to hear from anyone who has had similar problems. Still rate the car though!!!
Mondeo 2 Ltr TDCI Injector Problems - BobP
I have occasionally encountered a non start problem when the glow plug flashes and the engine turns over but fails to start.

The solution on each occasion was to reset the security system by operating the central locking remote controller. Locking and unlocking the system reset the security system that prevents starting. The flashing glow plug stopped flashing and engine started immediately.
Mondeo 2 Ltr TDCI Injector Problems - patent
I've had very similar problems with my Focus TDCi purchased September 2002: severe misfiring, poor starting, flat spots and hesitation on overrun.

RAC diagnosed faulty connection to No 4 injector and could make it misfire by wiggling the connection. Dealer replaced injector No. 4 and admitted that they had seen this before, but with No. 1. Similar problem but less severe occurred thereafter. Dealer reprogrammed engine management system and said that it should have been re-programmed when injector was replaced as the injectors were firing in the wrong order!!

Better now but I still have my doubts as it still hesitates and does not feel 100%. Last week it took 3 goes to get it started.

With regard to the flashing glowplug light, the RAC guy said that this was connected to the emissions sensor and presumably is sensing neat fuel during poor starting and misfiring.

Even though it has brilliant handling, it may well be the last Ford I buy. I had put off buying a Ford since 1977 (!) when I had an RS2000 Escort new with dodgy paintwork, faulty inlet/exhaust valves and appalling dealer back-up. It seems that not that much has changed in 25 years.
Mondeo 2 Ltr TDCI Injector Problems - frustratedmondeo
Hi all,

I have an August 2002 Mondeo TDCi 130bhp Estate. The car is leased through ArvalPHH and was brought into the Uk through a dealer in Newcastle. Since I have had the car I have had the same starting problem (especially in hot weather). On starting the car, the glow plug light goes out, but the engine just keeps turnign and it won't fire, turning the ignition on again, the glow plug light flashes and the car will not start unless I lock, deadlock and unlock it again. The other day, through shear frustration, I managed to get the car to fire with the glow plug light flashing and drove the car home, but it was running extremely rough, as though it was only firing on three cylinders and the glow plug light was still flashing. I guessed it was an injector fault, which I thought may be linked to an imobiliser problem. The car has been back to two different Ford garages who both claim to know nothing about the problem and cannot find anything wrong with the car.

HELP!! What should I do now? It is otherwise a great car, but I want it to be reliable. Any suggestions on what to say to the Ford garage before I cut the car up into small pieces and post it to Ford customer services?

Thanks

Gary
Mondeo 2 Ltr TDCI Injector Problems - Dave Gordon
The 3 most common problems with Ford TDCI injectors losing their coding is:
1) Air Mass Meter goes out of calibration. The car will not flag a DTC, because the meter is still registering air flow,the car runs poorly, loss of power etc, but the ECU will not be able to adjust the injector duration to compensate, and therefor drops the codes. Replace the Air Mass Meter and have some-one with an AutoDiagnos MultiTester Pro re-code the injectors.
2) The alternator overcharges, and the ECU drops the codes. Again, the injectors can be re-coded after the fault is fixed.
3) The injectors fail, but usually it is one at a time, not all See www.autodiagnos.com
Mondeo 2 Ltr TDCI Injector Problems - gb9
i wonder if that is the problem i have. my tdci 130 was running ok until a couple of weeks ago when it started to develop a problem at low load around 1800-2000 rpm. feels like the injection system cutting in and out. No warning lights come on and the engine does not cut out.
The only solution is to drop below 1800 rpm or pull above 2200rpm. only happens at low load like cruising in 40mph traffic, now got worse as it will happen at any engine speed on low load, go down a dip on the motorway at (err)70mph and it will shudder until you put a little throttle on.
Ran through the DTC display via the dashboard back door method and it came up with code P2900, my local ford dealer has never heard of that code and has no ideas.
Fuel consumption is up 30% and lots of crap out the exhaust but no major loss of power in acceleration or top speed.
Confuses the hell out of me, there is obviously a problem but i would expect an injector fault to effect performance and flag the warning light giving a P2338 type code. Wonder if its the MAF on the way out or even the throttle position sensor breaking down.
Any one had this problem or have any ideas?
One final thing while i remember, only happens when engine warmed up, cars fine for first mile or so in the morning then the moment i get hot air from the heater matrix the judder starts cutting in.
Mondeo 2 Ltr TDCI Injector Problems - Micky
P2900? Fuel air metering auxiliary emission controls?

{He writes, after a furtive google}
Mondeo 2 Ltr TDCI Injector Problems - Quinny100
The dashboard only displays fault codes that relate to the instrument panel itself - it will not display DTC's from the engine management or any other component on the car.

As for your problem, doesn't sound like it's injection related to me. The symptoms sound more like either an EGR valve problem or a turbo problem.
Mondeo 2 Ltr TDCI Injector Problems - Roly93
Have a look at this TSB :-

Model: Mondeo 2001 (Build Date: 10.2001 - 05.2002) (Build Code: 1K - 2J) (Engine: 2.0L DuraTorq-TDCi)
Focus 1999 (Build Date: 05.2001 - 05.2002) (Build Code: 1B - 2J) (Engine: 1.8L DuraTorq-TDCi)

Markets: All

Subject: Engine running erratically or does not start, due to contamination of fuel injection system caused by cam roller/shoe failure.

Summary

Should a customer express concern that the engine is running erratically or does not start, a potential cause (within the above mentioned manufacturing time period) is that the fuel pump is unable to deliver the required fuel rail pressure due to wear of the rollers and shoes. The damage is caused by insufficient bedding of the rollers during early life. This also creates metallic particles which can enter the high pressure fuel system and lead to injector failure. To rectify this concern, a revised fuel pump, new injectors and associated parts should be installed.

If this concern is present, it may be indicated by a flashing glow plug indicator showing that a fault has been detected.

Due to a number of misdiagnosed common rail fuel pumps, it is necessary to re-issue this bulletin. If any fault codes are present, these should first be investigated and resolved individually. If the concern is still present, a sample of fuel should be collected and analyzed to determine if insufficient bedding of the rollers has taken place.

I understood this as a well known problem with early TDCi Mondeo's.
Mondeo 2 Ltr TDCI Injector Problems - David Horn
Can imagine the damage metal swarf would cause when forced through an injector at 30,000 psi.
Mondeo 2 Ltr TDCI Injector Problems - Frances
Is this the original Ford MC directive? We have the same problem as everyone else. I would like to know if you have an original number i.e. their's for the directive. I used to work for them and have visited Parts Recall so know how they work!!!! If you don't know the number do you know where or if (?) I can access this on their site, or anywher else. Or any other info. We are desperate now, the car is a taxi, no work, no pay, big garage bills etc. Anyone with any ideals or wanting to join me in a crusade to get what we deserve please get in touch. I am not willing to let this go.
Mondeo 2 Ltr TDCI Injector Problems - ffvrs
hi,

the garage may be trying to save you money but I always understood that all injectors should be changed if one is suspected as faulty. If the fault does come back at least that element can be eliminated as the problem cause.
Mondeo 2 Ltr TDCI Injector Problems - Mr G
My mondeo is with Ford as we speak. I have told them that I am aware of the problems with the pump etc. I was told today that one of the injectors needed retuning and that they had checked the filter to be sure it was a 2 micron type. he said there was no sign of metal and that the car was now ok. This was a new filter in September so it may not mean much. We'll see!
Mondeo 2 Ltr TDCI Injector Problems - Micky
">he said there was no sign of metal and that the car was now ok<"

Good news. Ask for the comments in writing, keep all future fuel bills with mileage noted to demonstrate that only the finest diesel has sloshed through the system Ok, so that's a bit simplistic, but it might strengthen your case at a later date if required.
Mondeo 2 Ltr TDCI Injector Problems - Mr G
I have a letter from Ford saying that they knew of no problems with the injectors etc. I wrote to them when a friend of mine had to have a new set costing 1500 pounds. I now have a copy of the service bulletin which i intend to present to them as it is dated before I bought my Mondeo. Apart from these problems it is a great car to drive, much better than the Avensis I had to hire while mine was in dock
Mondeo 2 Ltr TDCI Injector Problems - ambo
My Mondeo is now in a dealership with misfiring, which has been diagnosed as two faulty injectors. However, the garage already seem to trying to escape from their warranty obligations stating that the fuel filter seems brand new - it was replaced ~10K miles ago, in the Autum. Given the problems faced by other on this forum, is there a definitive statement that is going to stop my dealer from going down the route of denial of service?

Does anyone have the seemingly incriminating 'TSB' from Ford in which they allegedly recognised the fault?

Any suggestions to save a long term debate with the dealership and Ford would be great.

Thanks
Mondeo 2 Ltr TDCI Injector Problems - kaiser
my 2ltr mondeo tdci cuts out when you apply the accellarator for more power, usually in 4 or 5th gear, normally when you are passing out another car. Its extremly dangerous.

The car is 3 months out of warranty, 80,000 miles, missing 1 service history.

I have written 3 times to ford who have ignored me. I've taken the car in to have it looked at, which I was charged 100 for the experience. They then told me it would cost 1000 pounds for 2 new injector pumps, 1 oil seal and cable.

To me this seems very unfair as the Mondeo 2 Ltr TDCI Injector seems to be a common manufacturing problem, is there any thing I can do to have this fixed without cost to me?


Mondeo 2 Ltr TDCI Injector Problems - TurboD
Not much help now , but read this site before buying any car, I did, and bought a 2l petrol Mondy. So far , no probs.
Look for cars with probs, then avoid- Ford TDCI seem to figure big time, can't all be poor servicing, can it?
Mondeo 2 Ltr TDCI Injector Problems - Micky
">is there any thing I can do to have this fixed without cost to me?<"

Change down to third or even second and then overtake like a proper driver, all this tomfoolery in the higher gears is the root cause of TDCi problems IMHO.

So, kaiser, tell me, how did you find this website?
Mondeo 2 Ltr TDCI Injector Problems - kaiser
found the website using google, this website content is excellent especially this thread and peoples comments.

I normally agree about changing down a gear, however sometimes when you are crusing along in a dual carriage and simply passing out a car doing 50, then ideally you should not have to change down to third or lower.

apart from that, its still quiet dangerous, to have your car cut out when driving along... ford should accept their responsibility for this design fault, it could cause an accident.

I have decided to get the car fixed by ford, are there any other design faults, I read about people replacing the tdci fuel system.
Mondeo 2 Ltr TDCI Injector Problems - cheddar
>> out a car doing 50, then ideally you should not have
to change down to third or lower.


Agreed, the TDCi is very torquey and it is simply not neccessary to change down under such circumstances.


You said before "The car is 3 months out of warranty, 80,000 miles, missing 1 service history", the warranty is until 60,000 miles however if the car is only three months over three years old you may have been lucky re goodwill if not for that missing service. i have found Ford and the local dealer excellent in that regard.

You also say "I have written 3 times to Ford who have ignored me", who to? where to? I recieved excellent service and had an attentive person assigned to my case when I wrote, at the time their CC was in Glasgow, it has moved recently and that they have had some contract staff involved who have been less than ideal, it perhaps should improve. I would write to:

The Customer Services Director
Ford Customer Relationship Centre
PO Box 4430
Coventry
CV3 9BH

Some dealers are better than others, "2 new injector pumps, 1 oil seal and cable." sounds strange, perhaps they mean two injectors, though the injectors can need reprogramming, has this been tried? should only csot about £50, mine needed one doing at around 70,000 miles, now on 115,000 and all fine - touch wood!

You say that this seems to be a common problem however in the scheme of things bearing in mind the shear number of Mondeos and also X-Types and Transits that use the same engines and / or fuel systems and the fact that they do above averaage mileages the number of problems are no worse than average.
Mondeo 2 Ltr TDCI Injector Problems - kaiser
Cheers for that.

When I wrote to them, it was an email threw the contact us on the website, sorry for the confusion. I will try your tact of the above address.

I have just come back from the garage with a list and cost
2 new injectors, 1 injector no 2 pipe, 1 injector no 4 pipe, 1 injector seal and 1 com corer- what ever that is...approx(900), both injectors will have to be recharged and tested.. I have a copy of the analysis done and what now worries me is this line . "May have further problems", I wonder is it time to get rid of the car.

also the people in the queue in front of at the garage had the same problem with a vauxhall, and they were treathing the garage with a solicitor...

I did try for Goodwill and may get 5% off the parts, goodwill comes in if the car is only 1 month out of warranty....

also good point about the reprogramming, when I called back the office was closed. will try this on monday, what that how yours was fixed?

The staff at the office were friendly but could do nothing in regards to costs.

In regards to a common problem, I've got that impression from for reading the internet and speaking to a mechnic at another garage.

All good stuff.
Mondeo 2 Ltr TDCI Injector Problems - Aprilia
I don't think that the TDCI's are necessarily any less reliable than average. The snag is that when you do get a fault it soon becomes very very expensive. I have a mate who runs a business fixing diesels for a living and as he puts it, "one wobble and you're into four figures". There are a heck of a lot of parts on a TDCI in addition to the basic engine management (i.e. dual mass flywheel, turbo etc) and its all high-precision engineered and expensive.
You will have to balance the cost of repair against the value of the car. Ford will duck and weave to avoid paying out on cars IN warranty, so I don't think there is much chance of any help out of warranty. If the car is driveable then consider a quick P/X against something else.
Mondeo 2 Ltr TDCI Injector Problems - Micky
Unless your prepared to slug it out with Ford in a small claims court then get rid of the thing. I'm sure there's a business opportunity for someone to install Duratec petrol engines in TDCis.
Mondeo 2 Ltr TDCI Injector Problems - kaiser
I did get through to ford customer services and after they reviewed the case, they were unable to assist me in anyway.
Mondeo 2 Ltr TDCI Injector Problems - ProtonGuy
My year old Mondeo TDCI also had the flat spot around 2000rpm which is quite common.

After a recommendation in the HJ letters page a couple of weeks back I got a bottle of Millers Sport4 diesel additive and it got rid of the flat spot almost immediately. Using this and well known diesel brands should keep the system clean too. No black smoke or misfires (touch wood).

I get between 40 and 45mpg with mixed driving.
Mondeo 2 Ltr TDCI Injector Problems - cheddar
I did get through to ford customer services and after they
reviewed the case, they were unable to assist me in anyway.


Write a letter, do NOT phone, phone calls are handled by junior staff, even agency staff, letters are taken more seriously especially if addressed to the MD or Customer Services Director. Dont give up.

The Customer Services Director
Ford Customer Relationship Centre
PO Box 4430
Coventry
CV3 9BH
Mondeo 2 Ltr TDCI Injector Problems - sampuk
My car is a 2005 2.0TDI Silver and with 16,000 miles, last week it needed two new injectors after similar problems. What future is there for me with a practically new car that is having problems now? The Customer Services Manager said that they had not any previous issues with fuel systems, on reading these posts this clearly was not true. I would like to pin Ford down and get this fuel thing sorted, I've seen where someone has said that if the poroblem keeps recurring Ford have to make amends by offering me some sort of compensation. As this is my first vehicle under warranty (and my biggest cash outlay) I am not just sure as to how to proceed with my concerns. I just don't trust the thing now. Any info/advice greatly appreciated.
Mondeo 2 Ltr TDCI Injector Problems - cheddar
My car is a 2005 2.0TDI Silver and with 16 000
miles last week it needed two new injectors after similar problems.
What future is there for me with a practically new car
that is having problems now? >>


There are loads of TDCis on the road and relatively few problems however those with problems gravitate towards a site like this, I have had one case of an injector needing reprogramming in nearly 5 years and 115k miles.

You have a lot of warranty left, if it is OK once fixed though dont worry, make sure it is serviced by a Ford dealer though.
Mondeo 2 Ltr TDCI Injector Problems - Micky
">I have had one case of an injector needing reprogramming in nearly 5 years and 115k miles.<"

And merely to balance Cheddy's offering, I've never had to have any work undertaken on injectors fitted to various cars in 400k plus, and 100k was in a deseail (although the fuel pump packed up at 100k). No TDCis though.
Mondeo 2 Ltr TDCI Injector Problems - 659FBE
This saga will run and run - obviously there are loads of these vehicles and their derivatives around and a proportion of these will give trouble. Transits are as bad as Mondeos.

What does concern me however is the quality of the fuel injection equipment specified by Ford. Ford are a highly cost concious and profit motivated Company and will not pay Bosch prices. The offending part of Delphi was formed partly by the acquisition of an old established UK fuel systems company which I had connections with. In typical US style, they got the business without the know-how. There is no small diesel capability in the US as economy is not on their agenda, hence the need for a European fuel systems operation.

I would suggest some careful thought before parting with money, taking into account the backup from the manufacturer. It's surprising how few of other makers' fuel systems are irreparably damaged by "water in the fuel" and other "misfortunes".

659.
Mondeo 2 Ltr TDCI Injector Problems - cheddar
Stats dont back that up, warranty figures suggest that Ford suffer far fewer fuel system problems than Toyota for instance. I strongly beleive it is a matter of the Mondeo being so numerous and doing above average mileage so even if the number of Mondeo issues are simply average there would be a lot more Mondeo issue reported on here than for most other cars and of course people with issues gravitate to a site like this.
Mondeo 2 Ltr TDCI Injector Problems - Red Baron
We've had a TDCi for 3 years now. Perhaps 6 times has the injector light come on in the dashboard, always from startup and associated with rough running (only firing on three cylinders?). A switch off, short wait, and restart cured the problem each time, followed by an italian tune-up. This has not happened for over a year now. Car still returns 45 - 52 mpg.
Mondeo 2 Ltr TDCI Injector Problems - Micky
Its not the fact that TDCis have these problems, it's the way the manufacturer treats owners that causes concern.

Other manufacturers take a different approach; this taken from a rather obscure motoring column:

">
I'm usually the first to complain when I receive a level of service below expectations and so feel I should publicly acknowledge BMW's goodwill. My March 2002 530d SE suffered turbo failure after 74,000 miles, two months short of its fifth birthday. I did not purchase an extended warranty as no previous vehicle of mine had suffered a catastrophic failure. The car was towed to Dick Lovett in Hungerford, where it was examined and a report sent to BMW along with a goodwill claim. BMW offered to replace the turbo, inlet manifold, catalytic converter and all four injectors. I was asked to pay the labour costs only, which amounted to £435 plus VAT. Dick Lovett also drained the intercooler and, after all the work had been done, examined the engine for consequential damage. Fortunately, there was none. I'm still a big fan and will certainly buy BMWs again.
<"

As an aside, does the 530d only have 6 injectors? I assumed it was a 6 cylinder needing 6 injectors.
Mondeo 2 Ltr TDCI Injector Problems - Micky
">only have 6 injectors?<"

No, "only have 4" Time to retire I think, 170 miles of making good progress on country roads with the top down has clearly eroded my mental faculties.
Mondeo 2 Ltr TDCI Injector Problems - nomorefords
I have had, and am still having the injection / glowplug light flashing problems listed in all the above thread, on my 02 plate 2L Ghia TDCI. 54,000 miles on the clock. It is in the local dealer as i write. At 52,000 miles I had a new No1 Injector in Feb 07 and had to return it two weeks later for a "re-programming". I was told at the time, with a shrug of the shoulders, that if it happens again i will need a new set of injectors. That leaves me staring down the barrel of a bill for £1,000. I will not entertain a plea of water in the fuel by anyone.
I have driven a considerable number of miles over my lifetime in both petrol and diesel vehicles. 80,000 miles in Vauxhall Astra Diesel , 2 Diesel Escorts to 78,000+ each; 1 Diesel Peugeot 306 still running round with my daughter in it at 110,000 miles. I have never, never ever had problems with water in fuel. Nor any other fuel injection related problems.
So Ford's argument is shot down there. It is obvious that the problem is a technical (quality) one as already described in several items in this thread.
Additional to this i have had the rear suspension sub-frame bushes replaced at a cost of £200, which i have also discovered is a common fault. I bet there's a thread on that one too! Again an obvious design fault because they modify the frame and glue the bushes in.
I think it is shocking that Ford can carry out their research and development at the expense of their customers. I would have thought the least they can do is make the replacements much cheaper. I suspect that they are passing the full mark up through on parts.
Anyway, I am now faced with the dilemma of keeping the damn thing, because i've spent so much on it, or getting rid and cutting my losses. Oh sorry - can't afford another car!
Mondeo 2 Ltr TDCI Injector Problems - googolplex
A quick search of my previous threads on TDCis will show how defensive I have previously been of the TDCi engine. Through bitter experience, however, I have now had to change allegiances, having recently been on the wrong end of a £500 bill for the no1 injector, and even more recently £1400 for a new turbo. [this has been documented on another thread over in discussion]. I have to agree with Aprilla and others who basically tell us to get rid of these things before the warranty expires. I was going well on a 4 year old car, but was then stung. I've taken the decision to swallow my losses, and insure against any others by going for the same car with the 2 litre petrol engine which I hope will eventually be a safer buy to keep beyond warranty (currently one year old). Of course it will go wrong; they all do. But hopefully it will not be as costly as the diesel. My old Cavalier diesel, in its time, had just about everything replaced that could be (bar the engine itself); in 165K miles I never paid more than £400 for a bill. Don't get me wrong, the TDCi is a fine car and a joy to drive. But it is ludicrous (and something of a modern day scandal) to expect private buyers to risk 4 figure bills for so many basic repairs. These comments are not confined to the Ford, but apply to all CR diesels - take a look at comments on that XTrail - a car I really would have liked, but for the issues with the engine.

I'm really not enjoying driving the petrol as much (except when stationary!), but then my confidence in the modern CR diesel has been shaken. I suppose, one day, I'll go back to them, but not before I've purchased as much additional warranty as I can pack in to a deal - warranty which will cover injectors, turbos and anything else which seems so expensive to mend.
So from my bitter experience, the advice has to be - get shot of it.
Splodgeface
Mondeo 2 Ltr TDCI Injector Problems - 659FBE
Good diesel fuel injection equipment is expensive.

Our American and Japanese friends have no interest in their home terretories in small diesels (or the planet), so they have to seek local assistance in Europe where the diesel market is too big to ignore.

Ford have linked with PSA, GM with Fiat/Isuzu in order to address this sector of the market. Ford and GM are highly profit motivated organisations and it hurts them too much to buy a fuel system from a specialist such as Bosch on a large scale (there will always be odd "bits").

Enter Delphi, a conglomerate of acquisitions, the diesel fuel systems part of which arose from the ashes of a UK specialist. They got the Company without the know-how. At risk of repetition, Delphi is to diesel fuel systems as FoMoCo was to carburettors - for all the same reasons - cost.

Buy a true European diesel with a Bosch fuel system, take good care of it and you will almost certainly reap the full benefits of an engine which is not constrained to run at a constant air/fuel ratio.

659.
Mondeo 2 Ltr TDCI Injector Problems - googolplex
OK, so which engines use Bosch? Which are the good diesels?
Mondeo 2 Ltr TDCI Injector Problems - 659FBE
My VAG PD diesel is all Bosch as is my partner's ancient Pug 106D. Neither has given any engine trouble, both have the water drained from the filter bowl at every service, both get Bosch fuel filters every 20k miles or so. Neither has ever been mis-fuelled.

659.
Mondeo 2 Ltr TDCI Injector Problems - TurboD
hey , i get 35mpg with my 2l Duratec, so why mess with those derv donkeys, leave them to the dumper trucks, it makes sense.
Mondeo 2 Ltr TDCI Injector Problems - cheddar
>>Enter Delphi, a conglomerate of acquisitions................

Buy a true European diesel with a Bosch fuel system>>


Utter carp 659, utter carp, ALL CR diesels are highly sophistcated and expensive to repair however there is no evidence to suggest Delphi systems are less reliable than others, yes a number of TDCi failures are reported however TDCis are also far more numerous than others and cover above average mileages, very few Jag diesel problems caome to light though it is the same engine, just far less numerous. If fact stats that are available such as Warranty Direct rate Ford fulke systems as more reliable and cheaper to repair than the like of Toyota.

Furthermore the chain cam Ford / Jag Delphi CR unit is so superior to the 40k cambelt change, VAG / Bosch cam driven PD pump unit in engineering terms as well as refinement and performance and at least its equal on efficiency that simply does not bear comparison.

My TDCi is coming up to 120k, it literally drives as new (and I have had it since new so I can say that), it required one injector reprogramming at about 70k (1/2 hour labour), yes it may have an expensive failure around the corner though it has saved iro £4000 over a petrol equivilent and at least £1000 in cambelt change costs over that mileage (40k, 80k, 120k) over a PD.


Nevertheless sorry to hear about Splodgefaces experiences.
Mondeo 2 Ltr TDCI Injector Problems - 659FBE
The current recommendation for the VAG PD engine cambelt change is 4 years/60k miles whichever occurs sooner.

I wish you luck with your Delphi fuelled vehicle - the nature of the problem is such that you may have got a good one - I hope so.

I have been in the diesel engine business for many years and merely comment upon what I find.

659.
Mondeo 2 Ltr TDCI Injector Problems - tyro
there is no evidence to suggest Delphi systems are less reliable than others


www.honestjohn.co.uk/forum/post/index.htm?v=e&t=42...2

The evidence may not be sufficient to prove the case, and yes, there may be far more delphi than denso units on the road, but that surely constitutes some evidence.

My recommendation is that if Splodgeface wants a good, reliable, CR diesel vehicle, he should buy Cheddar's - when (or should that be 'if'?) Cheddar decides to sell it.



Mondeo 2 Ltr TDCI Injector Problems - DP
Renault use a Delphi common-rail fuel system on the 1.5 dCi engine, and the odd EGR problem apart, which is completely unrelated to the fuel injection system, is regarded generally as a very reliable unit. My previous company ran a fleet of 30 or so Megane dCi 106's up to between 80,000 and 120,000 miles and not one suffered any form of fuel system failure. Electrical faults and build issues yes, but the reliability of the engines was first class.

I wouldn't begin to claim knowledge of similarities and differences between the Delphi system fitted to the Renault engine, and that fitted to the Ford unit, but I can't believe there is an issue with Delphi systems as a whole.

Cheers
DP
Mondeo 2 Ltr TDCI Injector Problems - cheddar
>> there is no evidence to suggest Delphi systems are less reliable than others
www.honestjohn.co.uk/forum/post/index.htm?v=e&t=42...2


The assertion in that link that the Jag uses a different fuel system is untrue, it is the same, the only difference is that the 2.0 Jag uses a 5 speed (Getrag IIRC) gearbox where as the 2.0 Mondeo uses the same 6 speed box as the 2.2 Mondeo and Jag.
Mondeo 2 Ltr TDCI Injector Problems - injection doc
the jaguar injection system is basically the same mechanicals but electronically very different with 5 pulse injector firing to shut the racket up. The electronics are totally remapped & designed by an outside company that jaguar put a lot of money into to improve the drive.
Interestingly enough jaguar have had an improved reliability.
I have had a 2ltr absolutley faultless & now a 2.2 & the performance is staggering for a diesel & drives very differently to a colleges 2.2 mondeo so he was very dissapointed in the dofference in noise & performance
Mondeo 2 Ltr TDCI Injector Problems - jag man
the jaguar injection system is basically the same mechanicals but electronically very different with 5
pulse injector firing to shut the racket up. The electronics are totally remapped & designed
by an outside company that jaguar put a lot of money into to improve the
drive.
Interestingly enough jaguar have had an improved reliability.

I have a leased 54 Jaguar x-type 2.0S.
Since new it has suffered the 1800rpm hesitating as per the above comments.
I have been through 3 Jaguar dealers service departments, at one visit there were 3 X-types in for the same problem.
The car has had several engine management re-programs, and it has had the entire fuel system flushed, with new injectors and new pump. Sometimes the car was better for a short period of time, but never fixed.
Three years later I still have the same problem, in fact it is now worse, hesitates at 1500, 1800, and sticks at 500 rpm when started for about 15 seconds.
The last Jaguar dealer said "There is nothing more we can do, we are awaiting a fix from Jaguar" ?
Is there a definite fix for this problem, that I can go back to the dealer with ?

Luckily my lease car is up for replacement soon, I will definately be avoiding anything with the ford TDCI engine.
Mondeo 2 Ltr TDCI Injector Problems - injection doc
Jag Man. Is the hesitation slight & just an iritation? if so have you tried driving with the AC off just to see if its that!. My 2.2 had a real hicup as you went to pull away, Diconnected the battery overnight, restarted in the morning & drove it gently for 500 miles learning curve period ( checked with jag ) including used 2 cans of DAE speciffically recomended fuel system cleaner in full tank of fuel (DAE find on net ) & hicup gone & has never come back. With AC on I do notice a hicup at 1800rpm but never with it off.
You could also try when cold running it at 1250 1750 & 2250 rpm static hold dead steady at these speeds & if it starts to run lumpy at all it needs injectors recoding. My jaguar dealer was useless as they don't have experience of diesels in general but I touched base with a specialist who sorted recoding on 2.0d for me a couple of years ago.
Mondeo 2 Ltr TDCI Injector Problems - cheddar
the jaguar injection system is basically the same mechanicals but electronically very different with 5
pulse injector firing ..........Interestingly enough jaguar have had an improved reliability.
........ drives very differently to a colleges 2.2 mondeo so he was very dissapointed .............>>


This differs from what I have been told, new gen updates have at various times been introduced first on the Jag or the Mondeo, the first X-Type 2.0d was a generation ahead of the Mondeo for a while and was more problematic for it until the bugs were ironed out, Jag dealers at the time did not have the knowledge and often sent the cars to the Ford dealer. Perhaps your 2.2 X-Type is on a different level from the 2.2 Mondeo you mention.

I remember a roadtest claiming that the Jag was "so much more refined than the Mondeo it is based on" though it transpired that they were comparing it with a TDDi not a TDCi.
Mondeo 2 Ltr TDCI Injector Problems - googolplex
My recommendation is that if Splodgeface wants a good reliable CR diesel vehicle he should
buy Cheddar's - when (or should that be 'if'?) Cheddar decides to sell it.


No disrespect to Cheddar or his car, but I've had my time with diesels for a while. Time to give the other side a run...
Splodgeface
Mondeo 2 Ltr TDCI Injector Problems - Bill Payer
I've just been agonising over whether to pay near as dammit £1000/yr for MB ServicePlus (service and repair cover) on my 3 yr old Mercedes with the old 2.7L 5cyl common rail diesel engine.

Reading this made makes me glad I decided to go for it!
Mondeo 2 Ltr TDCI Injector Problems - TurboD
Yes some TDCIs seem great - but can you gamble with that sort of cash?
I wouldn't but others need to make their own decisons after reading as much as possible.
Also, the driving experience is different on a diesel as compared to a petrol, you do get something for your money.

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