Ford diesel engine needs replacing - Pancholi
Hi

I could really use some knowlegible advice on a faulty car I have.
The car is 2003 Mondeo. It was brought from my cousin who had it from new, now it has 74000 miles on the meter but always serviced by Ford.

Two months ago it ran really bad and I took it to the dealer. They said the injector was bad and needed recoding, they also said the software needed upgrading (I thought only computers needed upgrading). This cost £120 because the Mondeo has too many miles to be within the warranty.
The car ran better for a while but then started its tricks again, like really rough running and knocking, like a bag of bolts.
I went back to the dealer with it and they said it had a faulty injector, so I asked them to replace the injector. This cost £393.
Again the car ran ok for a time but then started running really bad and knocking. Last week they collected the car and now they have examined it and told me that one of the con rods is a bit bent. I will have to pay for a new engine or the old one to be disassembled and rebuilt with new parts for several thousand pounds. I would be interested if anyone can say how this can happen, since the car use to run perfectly and only Ford dealers have worked on the car. Has anyone else had this trouble? Information would be welcome.
Ford diesel engine needs replacing - Micky
Get a 2nd opinion from an independent diesel specialist.
Ford diesel engine needs replacing - massey
Pancholi, post your message on the 'technical matters' board on thisback room site

www.honestjohn.co.uk/forum/threads.htm?f=4


Ford diesel engine needs replacing - Hamsafar
First of all, get your money back for what they've done so far.
If they don't do this, sue them via
www.moneyclaim.gov.uk/csmco2/index.jsp
Then take it elsewhere, they obviously just guess while having you fund their experiments.
Ford diesel engine needs replacing - Quinny100
When it ran rough, was the glow plug lamp flashing?
Ford diesel engine needs replacing - Pancholi
Yes the glowplug light was flashing
Ford diesel engine needs replacing - cheddar
I have heard of a TDCI with a bent rod caused by flood water sucked in through the intake which is situated low on the left hand side of the car. Have you been though any large puddles / floods? Many modern cars have intakes thus situated.
Ford diesel engine needs replacing - Aprilia
Bad luck on this Pancholi.

I have heard of this happening on CR Diesel engines and I gather its due to serious over-fuelling from the injector. Because of the very high fuel pressure it is possible for a fault to cause a lot of fuel to be injected in a very short time - this can cause very high pressures in the cylinder which can then bend a rod (typically the rod ends up only a few mm shorter - but this throws out the compression ratio and causes the engine to run very badly).

The way these injectors work is that a more-or-less standard injector is used by Ford and then its performance is adapted/programmed to the individual engine so that it delivers the right amount of fuel on each cycle. The coding is done electronically via something like the WDS tool and the technician uses the code number (hex format) on the cylinder head by the injectors.

For some reason known only to Ford the injectors sometimes seem to randomly lose their calibration - it sounds like this happened, first time around, to you. The glowplug light flashes, engine runs rough and the injectors need recoding.

Looks to me that somewhere along the line (because of a mistake by a technician or due to some other fault) a lot of extra fuel ended up in the cylinder and damaged the engine. Proving who/what was at fault is probably impossible now.

Typically they will turn the engine to TDC and measure height of each piston below the head - bent con rod will then show up - I bet this is what they've done and are now reporting to you.

There is no solution but to rebuild or replace the engine - it will never run properly now. This will be a long process (i.e.. lots of labour) because this engine has a complicated fuel system and a turbo to deal with. Its a long job if its stripped and rebuilt. Getting a s/hand engine is not going to be easy either. A brand new engine is not economically viable on a three year old Mondeo. Will it limp to an auction?

Still, they are very economical cars when they're running properly, aren't they..... Best of luck with it.
Ford diesel engine needs replacing - rtj70
Best of luck Pancholi. I too have Mondeo TDCi problems again. Not stealing your thread but sharing experience.

My TDCi (just out of warranty too) is mibehaving again.

Travelling on M6 on Thursday it seemed a little hesitant to rev, and then tried flooring it. Brief pause, revs went to 3000 but no acceleration, and then with foot firmly to floor revs dropped to 2000. Having had two EGR valves fail before pulled into slow lane and got into the approaching services. Called AA and they were obviously stumped with a stationary vehicle. Plan was to drive to next junction with AA behind and then try driving the 50 miles home on A34.

Got home and car in with Ford. They look at it and no fault codes. Up on ramps and they spot a split bush (bushes replaced before and not sure which it is this time) and it has a fuel leak and needs parts before a road test. Not sure where the fuel leak is and whether one could cause the symptoms above. They also "re-programmed it" and tell me "it accepted it" whatever rubbish that means. Perhaps this is the so-called injector re-programming?

I really hope you get yours sorted. I await the call tomorrow from Ford. I am just glad mine belongs to Leaseplan who will foot the bill and not me and I currently have a Zafira 1.9 CDTi as the hire car.... and its diesel engine seems very refined compared to the TDCi but lacks power/torque.

Rob
Ford diesel engine needs replacing - Quinny100
I've heard of one other instance of this which was put down to the owner running the car for a long period with the glow plug light flashing due to a faulty injector. The imbalance in cylinder pressures can bend a rod as Apriila said. Moral of the story is that if it is running rough due to a faulty injector get the trailered to the dealer if it's more than a few miles away.
Ford diesel engine needs replacing - Aprilia
That's a fair point Quinny - however for the average owner its probably a case of if they can limp home then they will. I suspect if there is massive overfuelling then rod will bent in a matter of a couple of rotations of the engine - either that or something else will give. The fact that the OP's car ran OK after initial recoding makes me think that damage must of been done later and by the Ford dealer.....but impossible to prove.
Ford diesel engine needs replacing - rtj70
Quinny if the reference was to me.... no lights flashing om the dash and no error codes at dealer. If I saw any of this I'd stop when safe. In fact a few months back the car was at the dealer due to me insisting on poor mpg. Reprogrammed and said nothing wrong.... hhhhmmm. Now a leak.

I could have got it trailered and would but AA thought driveable. And not my car hence worth the risk. My car... not worth the risk.

I have a call to make to a colleague tomorrow related to my problem. He had a Jag X Type TDCi and after lots of fuel leaks, Leaseplan took the car off our fleet (won't name my company as irrelevant).
Ford diesel engine needs replacing - rtj70
Apologies Quinny. Saw your post above now about the light flashing and he confirmed it was. Doh from me and for OP.
Ford diesel engine needs replacing - Grease_monkey
Has it prior to this problem been smoking more than normal? More black smoke? I would not have thought that they have removed the cylinder head to check piston heights so have they carried out a compression test. what exactly have they said to diagnose the conrod.
Ford diesel engine needs replacing - Pancholi
I visited the garage today. They have found out that the con rod is bent by using a measuring probe through the cylinder head. It is bent by 2mm. The engine will no longer run properly and needs repairs.
Ford diesel engine needs replacing - Aprilia
Yes, they would turn the engine to TDC and measure distance down to piston crown for each cylinder. They probably took a compression check to confirm. End of the road until the engine is rebuilt or replaced.... Welcome to the wacky world of CR Diesel.....
Ford diesel engine needs replacing - cheddar
To be fair Aprilia it may not be CR related, as I said above I have heard of a TDCI with a bent rod caused by flood water sucked in through the intake which is situated low on the left hand side of the car, many modern cars have intakes thus situated.
Ford diesel engine needs replacing - Aprilia
If it was water ingestion I would expect more than one cylinder to be affected, water found in engine and more major bending of con-rod. 99.9% sure this will be overfuelling - heard of this exact same thing happening on other engines. I bet it will be on the cylinder he had the problem injector too.
Ford diesel engine needs replacing - cheddar
>> I bet it will be on the cylinder he had the
problem injector too.


If so he should have a claim against the garage / dealer.
Ford diesel engine needs replacing - rtj70
Got mine back today. Leaking diesel supply to Common Rail. not sure exactly where. Not had a chance to test drive yet but it sounds different..... And different to how it has sounded for a long long time.

Starting to wonder about CR injection systems.

Would not like to guess the bill... 50k service, rear suspension bushes, front and rear disks and the diesel leak. Not my car luckily as it is out of warranty by about 3 weeks.
Ford diesel engine needs replacing - Pugugly {P}
SWMBO has just been browsing these diesel tales of woe, cue the replacement for the MINI next sppring, she'd set her heart on an Audi A3 TDi, now re-considering a late reg Quatrro (Gad! Thanks guys)
Ford diesel engine needs replacing - Xileno {P}
Dear Mrs Pugugly. The Audi TDi is actually very reliable being PD rather than Common Rail. It's therefore a far better proposition than a thirsty Quattro :-)
Ford diesel engine needs replacing - Collos25
If you do need a new engine you will not have to spend the thousands of pounds requested by your local friendly ford dealer have a shop around I think you will find much cheaper alteratives.
Ford diesel engine needs replacing - Menzies
Pancholi, As a former TDCI 'sufferer' I feel your pain. I had a Mondeo that played up, threatening a £2000+ bill but fortunately it would still run and I ended up managing to p/x it for a Honda Accord. I can only say that the Honda is streets ahead in every way. The build quality is in a different league. My Mondeo had that 'old car' feel after only two years of normal use.
Ford diesel engine needs replacing - rtj70
Looks like mine also needs a new clutch at 47k or at least some repairs... so it's apparently a 4-5 hour job at £75/hour without parts for a clutch on one of these Mondeos.... The front suspension needs dropping or something like that. So call it £375 plus parts then.
Ford diesel engine needs replacing - Aprilia
Good idea to check out the clutch hydaulics and replace the slave cylinder while the gearbox is off. Could save a lot of money in the long term - they sometimes fail and go 'sticky' or leak.....
Ford diesel engine needs replacing - TurboD
You may need a new flywheel too on a Ford Diesel- it is a DMF which splits in two later.
(The petrol ones ar every nice, and cheaper)
Ford diesel engine needs replacing - lchris21
As TurboD says:

DMF !!!!!!!!!!!!!!!!!

Checkout my saga here:

www.vwaudiforum.co.uk/forum/showthread.php?p=9185#...5
Ford diesel engine needs replacing - Aprilia
To be honest Ichris21, 120k for a DMF sounds reasonable. You state that you expect the component 'to last the life of the engine'. A DMF is a multi-component assembly and there are parts that move and flex as it operates. How long they last depends upon how the car is operated (as with the clutch) I suspect yours have reached the end of its life and you'll just have to accept the bill. I am doubtful that VAG would see it as an abnormal failure.

My personal view in 'modern' diesels in general is that they are good buy if you will build up a high mileage in a short space of time (e.g. 20k+ per annum). For drivers doing more around the average 10-12k then the added complexity (DMF, turbo, complex fuel system) makes them a liabillity.
Ford diesel engine needs replacing - rtj70
Totally agree Aprilia.

Mine is a company vehicle and so I do not pay for maintenace. When choosing the Mondeo TDCI EuroIV variant in 2003 I took into account monthly costs to me (I pay tax on the BIK), personal mpg (I claim back business miles, likely cost of fuel etc. Since a Euro IV engine back then was not liable for the extra 3% BIK it came out cheaper than a lot of other petrol cars including a petrol Mondeo.

When I do this again in July/August for the replacement I will again take into account everything I did before (I got a cost to me figure per month). I will also look at cost of opting out and taking the money but if I did I do not think I'd risk a CR diesel. And I like diesel engines now because of the torque and mpg.

Note my personall mileage is around 10k and saving with a diesel over a petrol. But i do not carry the risk.

I have so many colleagues who opt out and say they are saving loads but they probably do not budget for when things go wrong. Since last Thursday I had a hire car for about a week. Paid for by the company on company insurance at corporate rates (about £25/day). But if I opted out I'd have had to provide a car for that time out of my pocket.

Ford diesel engine needs replacing - cheddar
Note my personall mileage is around 10k and saving with a
diesel over a petrol. But i do not carry the risk.


Not if the opt out car is warranteed, remember a CR will save you around £350 per 10,000 miles v a similar petrol so assuming you do around 20k p/a, 10k private and 10k business, the car will be waranteed until 60k / 3 years and you will have saved over £1000 just in private fuel costs. Therfore even if you take it beyond the expiry of the warranty and do "carry the risk" you would have to have a hefty bill at say 4 years and 80k to eat up the £1400 you would have saved in fuel.
Ford diesel engine needs replacing - Blue {P}
Like say, the bill for a new engine, not to mention the associated problems that come with losing your wheels for a fortnight? :-)

Seriously I found my CR diesel didn't even give me particularly spectacular economy, certainly nothing that would justify the risks of DMF failure, injector failure etc. I went from a TDCi Focus to a 2.5 petrol 3 series and have gone from 37mpg tp 26mpg, sure it's a hefty drop, but in exchange I get a more powerful, more flexible and smoother engine that doesn't give me any cause for concern regarding it's reliability... Once you then take into account that petrol is 5p cheaper than diesel, I would have to be doing a LOT of miles before I would consider CR diesel to be worth the risk again...


Blue
Ford diesel engine needs replacing - rtj70
Blue I so so agree.

My example of 10k personal pa and then Cheddar brings in 20k.

When selecting this company car I factored in income tax payment (taking into account BIK for a pre 2006 Euro IV diesel), MPG, personal mileage, decent performance, not so bad for the environment, etc. And also considered opting out and paying for my own car with the decent allowance. Even had petrols in my list but back in 2003 a Euro IV diesel was exempt from the 3% BIK charge. Next year I will do the same and decide what I'm really better off with per month. Could be a petrol next time.

Figured I was no better off with my own car per month (taking into account real costs and not having £18k cash not tied up to buy the car without some form of loan). And reasons why I was right again (for me):

- Warranty or no warranty, have had car off road for repair for many weeks in total over three years (same for previous VWs).... And in the past had car off the road due to an accident that was considered my fault (about 8 weeks!)
- Hire cars cost me nothing and even wangled a rather nice Alfa 156 when my car was in an accident - only meant to get a 1.4 Focus type car.
- Current car has lots of scratches (latest a keying down one side)

Ford diesel engine needs replacing - cheddar
My example of 10k personal pa and then Cheddar brings in
20k.


And you are not reading my post!

To try to make it clearer I said a CR will save you around £350 per 10,000 miles v a similar petrol so assuming you do around 20k p/a (in total of which 10k is private and 10k business), the car will be waranteed until 60k and 3 years and you will have saved around £1050 just in private fuel costs (i.e. of the 30k that is private, a saving of £350 per 10k) . Therefore even if you take it to 4 years and 80k (another 10k private so another £350 saved) you would have to have a hefty repair bill at say to eat up the £1400 you would have saved in fuel.


Blue's example is totally irrelevant because anyone with a diesel Focus that is only doing 37mpg would surely get it fixed, it should be averaging at least 47 mpg.

I base may calc on approx:

Petrol 10,000 miles @ 32mpg = 303 gals = 1375 ltrs @ £ 0.90/ltr = £1238
TD 10,000 miles @ 48mpg = 208 gals = 945 ltrs @ £0.95/ltr = £898

Ford diesel engine needs replacing - Collos25
I have had my mondeo 1.8 petrol nearly six months now and it averages 37.2 mpg and I would never go back to diesel all the diesel cars in my family except the xm 2.5 have all caused extensive expensive problems when they have around 80k on them.
Ford diesel engine needs replacing - Blue {P}
Cheddar - Quite how you can say that my example is irrelevant is beyond me, I owned and drove the car for a year, during which time I made many vists to Ford dealers getting updates, replacement EGR valves etc. Despite this it was impossible to get the car to return more than 37mpg.

Many, many other Focus owners at FFOC had similar experiences to me, so, IMHO, one other drawback of buying CR diesel is that you take the risk of getting a bad'un that doesn't return the MPG you are expecting.

Blue
Ford diesel engine needs replacing - cheddar
Cheddar - Quite how you can say that my example is
irrelevant is beyond me, >>


Cos typically a Focus TDCi 115 or 100 will average nearer 50mpg and much more if driven gently, 37mpg for one is an exception not the rule.
Ford diesel engine needs replacing - Pancholi
I am looking at my thread during my lunch break and its amazing how many responses there are. Thank you.

I tried all last week to find a replacement engine for my mondeo but without any luck. Engiens for sale are either much to expensive or worn out. I spoke to a Ford sechonhand parts supplier and they told me that parts are in very short supply lot of people wanting parts for these cars, you can put your name on a list. A new engine from Ford is much much to expensive so I am now selling my car on Autotrader as a salvage car. I am going to buy a Subaru.

Economy on Mondeo diesel is not what Ford say it is. You do not get 45mpg, I could not get more than 40mpg and more towards the 37mpg reported by other people. It is an estate though and so maybe heavier so making it less economical.
Ford diesel engine needs replacing - cheddar
Economy on Mondeo diesel is not what Ford say it is.
You do not get 45mpg, I could not get more
than 40mpg and more towards the 37mpg reported by other people.
It is an estate though and so maybe heavier so
making it less economical.


The poor mpg is probably due to an underlying problem that perhaps lead to the issues mentioned in your first post. You DO get 45mpg plus, mine has averaged between 47 and 48mpg over 111,000 miles. An estate will achieve 45mpg.
Ford diesel engine needs replacing - Happy Blue!
As much I will welcome you to the select club of Subary motoring, you do of course realise that the economy is poor. My Outback does about 30mpg on the motorway and 18mpg around town. But it is a 3.0litre auto!
Ford diesel engine needs replacing - Collos25
Just had a little google around including yellow pages and came up with 18 different companies that can recon this engine with free collection and delivery with some offering 24 hour service and thats in 3 minutes ,somebody is going to make a mint out of this car.
Ford diesel engine needs replacing - Blue {P}
Cheddar - clearly whatever I say won't persuade you that 37mpg is not unusual for a TDCi Focus, to everyone else, I would say that this is a fairly common problem with the TDCi Focus (the MK1 at least) and was reported by *many* other users on the FFOC forums, nobody had success in getting it fixed and believe me between us we tried virtually everything. (I also tried several different dealers in case my local were simply incompetant)

This trend with Focus was also noted during my time working in a Ford dealer where I had experience of many different TDCis rather than basing my view on one experience of a Mondeo. (As an aside I would say that the Mondeo TDCi always seemed a better bet than the Focus based on my experience of them)

Anyway, regardless of whether it's an exception or a rule, it proves my point that CR is not the last word in efficient and reliable engines, I've never had problems with a petrol engine like that and I would have to do some serious mileage before I would consider CR to be worth the risk again, however, I am pleased for people like Cheddar who obviously haven't had the same bother and benefit from a nice powerful engine that returns good economy.

Blue
Ford diesel engine needs replacing - Aprilia
Just had a little google around including yellow pages and came
up with 18 different companies that can recon this engine with
free collection and delivery with some offering 24 hour service and
thats in 3 minutes ,somebody is going to make a mint
out of this car.


I guess we have to assume the OP is bright enough to have called around and costed the job up. At the end of the day you can 'recondition' any engine, but at what cost? He is probably looking at 10 hours labour to do the whole job (inc. transferring ancilliary components, sorting out air con etc etc) - so let's say £50/hour at an independent - so that's £500 for starters.

Many reconditioners want the old engine to be what they call 'servicable'. If he is honest and tells them it has a bent rod then they will probably slap a big surcharge on it. A standard petrol Ford 'Zeta' engine (1.6, 1.8 etc) is around £850 properly reconditioned. I would imagine a TDCI is substantially more than that. So he could be up to £1500-2000 to sort the engine. Once he's done that then he still needs to sort out the injection problem that damaged the engine in the first place. Who knows how much that will cost?
I suspect there is some profit in buying and repairing this car, but not a 'mint'. I can understand why he's ditching it. A lot of folk are keen on diesels and depending upon how he advertises it he could get a reasonable price for it as salvage. They'll probably underestimate the work involved.
Ford diesel engine needs replacing - quizman
>>Cos typically a Focus TDCi 115 or 100 will average nearer 50mpg and much more if driven gently, 37mpg for >>one is an exception not the rule.

No it's not, my Focus will not do more than 40mpg however it is driven. On local short runs it does 38 mpg, that is messured brim to brim. We had a ZX TD which did more miles per gallon than this. Why should so many owners have to be guinee pigs for Ford? Other makes seem to be better, or is it that there are more diesel Ford's on the road.

I like diesel cars, they are better for short runs especially. We had a petrol Escort that used to mayonnaise the oil.

Just think, in the last couple of months we have gone from Mondeo TDCI is the best thing since draught bitter, to Ford diesels are a load of rubbish.
Ford diesel engine needs replacing - Aprilia
On the mpg issues I think in the latest Which? Car Buying Guide they stated that Mondeo diesel mileage was about 7mpg less than Ford quoted. I think Ford quoted 47mpg - so that's about 40mpg on the Which? test then.

In terms of problems with CR diesels - well yes, Ford TDCI's are popular. However Ford petrol cars are much more popular and there are literally millions on the roads, yet how many major petrol injection faults do we read of on here? Not many. I suspect the odd case that surfaces here is but the tip of the iceberg. I also think that PSA and Renault CR diesels are no less troublesome.
Ford diesel engine needs replacing - Statistical outlier
I'm spotting a thread here on mpg. Honda CR diesels also do about 7 mpg less than was claimed for them.

VAG group PD diesels appear to actually do the 50 mpg they are claimed to do, according to both my parents and to others on here. PD would appear to be a more efficient, albeit marginally dirtier and more noisy solution.

Do we learn from this that CR gains in driveability and cleanliness are offset by greater fragility and thirst. It's looking that way to me at the moment. I'd certainly not entertain buying a CR diesel other than as new.
Ford diesel engine needs replacing - TheOilBurner
Too early to say about fragility yet, but my CR diesel (Vectra 1.9 CDTI) does 50mpg, that's about 3 better than the official combined.

Mustn't grumble :)

How can we be sure that it isn't just certain cars/designs that are problematic? How many people who are happy with their economy and are having few/no problems will be coming here and complaining? Are all CR diesels really so bad? Or is it just some? We all know of various petrol engine designs that have been troublesome over the years or whose economy never comes up to scratch, why shouldn't CR diesels be any different?
Ford diesel engine needs replacing - Statistical outlier
There are people out there that get the claimed 50 mpg from the Accord, including some on this forum. Honda admit that they are not sure why, and have now altered their literature and advice to say 42 mpg (I believe).

As you say, all cars differ, and I would put money on the difference between my parents and I being at least partially due to driving styles, but even so..
Ford diesel engine needs replacing - IanJohnson
To ensure both sides are heard - My Honda is averaging 50mpg - about what they claim.
Ford diesel engine needs replacing - cheddar
On the mpg issues I think in the latest Which? Car
Buying Guide they stated that Mondeo diesel mileage was about 7mpg
less than Ford quoted. I think Ford quoted 47mpg -
so that's about 40mpg on the Which? test then.


Which state that they averaged 42.2mpg, this is not a survey of Which readers, it is the Which road test consumption.

Mine has averaged just over 47mpg over nearly 112,000 miles, that is not by the trip computer, rather (sad I know) I have charted it in Excel. I also note from other forums that 47 plus is normal, I have achived over 55 mpg on a gentle run, it must dip to aropund 42 ish around town.

In terms of problems with CR diesels - well yes, Ford
TDCI's are popular. However Ford petrol cars are much more
popular and there are literally millions on the roads, yet how
many major petrol injection faults do we read of on here?
Not many. I suspect the odd case that surfaces
here is but the tip of the iceberg.


Not the tip of the iceberg, as Micky said on another thread type "TDCi problems" into Google and see what site is on top, yup this site, honestjohn.co.uk!


Also as I said in another thread there is no evidence to suggest that some CR diesels are significantly more reliable than others, although there have been a number of Mondeo's featured recently on here the Mondeo is many times more numerous on the road than most others and covers a higher than average mileage, to reinforce this point there have been no references to the X-Type which uses the same diesel engines and same componentry as the Mondeo, the reason is that X-Types are far less numerous than Mondeos.

Furthermore where are all the posts about CR failures on Transits, Sprinters, Vitos etc, there are loads on the road, driven hard with mega mileages, no evidence of exceptional repair costs there AFAIK.
Ford diesel engine needs replacing - Aprilia
My mate repairs lots of Merc CDI's. To be honest although they do suffer from quite a few problems they don't seem to suffer the major pump failures that Ford suffer. A common failure on the Merc is the fuel rail pressure sensor, which goes faulty and throws the system into limp-home. Major symptom is poor starting. Its not an expensive repair (couple of £100's). Other than that its glowplugs sticking, MAF faults and the odd injector failure (which IS expensive). I believe there is a regular poster on here (Espada ??) who bought a Merc CDI and had it fall off its perch.

I'm guessing that a large proportion (30% or more) or CR diesels are still within three year warranty (most sales of this technology were post-2000 and as sales have grown a goodly proportion will be post-2003). It will be interesting to see what happens as more cars come out of warranty and the full economics of repair decisions have to be taken into account.

As regards the mpg - yes the Which? figure is about 42mpg - obtained during their testing in mixed driving. Obviously mpg will vary depending on usage pattern. I'm sure a Mondeo TDCI could hit 50mpg at a steady speed cruise under the right circumstances. My wife's old Primera 2.0i (150bhp) could regularly hit 38mpg on a longish motorway journey, but normally averaged around 32mpg in mixed driving.

Anyway, I've become bored with the whole CR debate and seeing the same arguments repeated time and again (including my own!). I guess you pay your money and take your choice....
Ford diesel engine needs replacing - PhilW
"Anyway, I've become bored with the whole CR debate and seeing the same arguments repeated time and again "
Same here Ap, I'm opting out, but rest assured I will be on here when things go wrong, and you may be able to say "I told you so"!! ;-)
regards
--
Phil
Ford diesel engine needs replacing - cheddar
>>Anyway, I've become bored with the whole CR debate and seeing the same arguments repeated time and again (including my own!). >>


Likewise Aprilla, just as it takes more than one Swallow to make a summer, it takes more than a handful of component failures to write off a whole genre of automotive technology.

CR is very common place now and is basically reliable, the scare stories have been with us before re the mass market introduction of ABS though ABS systems have proved to be very reliable and component costs have come down.


Ford diesel engine needs replacing - rtj70
Cheddar

At times I'd like your around town MPG when out of town. Around town I'd say my Mondeo TDCi is in low to mid thirties in traffic. Starting to wonder after the fuel leak and clutch/DMF failure at 47k that things might improve? Can only hope.

Note my car was one of the early TDCi 2.0l Euro IV diesels. Might be significant? How many on here with Euro IV TDCi engines? Very slightly higher MPG and CO2 but lower NOx. This engine does not have a particulate filter and burns the particles off more efficiently somehow... but does it impact performance, economy and reliability? But you cannot get a Euro III TDCi new now anyway.

Got mine shortly after they were available thinking:

- Newer version of the TDCi so might not have EGR failure (and got 2)
- Saved on income tax due to Euro IV diesel

On motorways cruising I might get around 48mpg though. Best when is driving at 50mph on clear A roads and then about 57mpg according to trip computer.

Final point.... Euro IV engine is all about lower NOx and particulates and therefore thinking this really does make a difference. I have never had as good MPG as I thought. But miles better than a Passat 1.8T :-)
Ford diesel engine needs replacing - Menzies
Cheddar

I wish I shared your benevolent view of TDCI. Those of us poor unfortunates who were asked to drop £2000 into the dealers lap to repair our TDCIs can be forgiven for taking a different view. I had an in-warranty car with a problem that neither the dealer nor Ford would acknowledge as a component failure. And I know from talking to an independent repairer that I am far from alone. These cars need a bit more development work. Once bitten and twice shy as my dad used to say.

Your fuel economy figures are also very optimistic. My overall economy never reached your town figure. As the other chap said, it was more like low to middle thirties in town and forty to forty-five at best on a run. Mine was a 2003 model so I dont know if it had Euro3 or 4 or an EGR.

Baz
Ford diesel engine needs replacing - cheddar
Baz,

Unfortunately there will certainly be a small number of people in your position for every model of car ever sold though as I said it takes more than one Swallow to make a summer so just beacuse you have had such an unwelcome experience it does not mean that every similar car on the road will be struck down with the same affliction. Yes there have been a few instances on this site recently though those with problems gravitate to a site such as this and if you Google the issue this site is top of the list so clearly it is not an issue featured prominenty within other such forums.

Also you mention that your car was in warranty, with respect and if I recall correctly, I and one or two others suggested approaches that *may* have acheived a result for you under warranty though, again IIRC, as is your prerogative you were unwilling to proceed in that direction. As Aprillia says, you pays your money and takes your choice.


Regards.

Your fuel economy figures are also very optimistic.


Not optimistic at all, realistic, they are what I achieve.
Ford diesel engine needs replacing - Quinny100
Ford Euro IV diesels are slower and use more fuel than Euro III's, particularly on the 2.2 TDCi engine. One of the parameters for Euro IV is that the catalytic converter has to be operational within a short length of time, so the ECU overfuels the engine when cold to heat the cat up faster. On longer trips this makes a neglible difference, but on short town runs where the engine isn't getting up to temperature quickly then it will have a greater effect.

Both my Mondeo TDCi's have been Euro III - I couldn't see the point in buying a IV as there was no advantage to the private buyer. Whether this will change in the future I don't know.

NOx emissions cause acid rain, some say particulates cause respiritory problems but seeing as they fall straight to the floor and the tailpipes on diesel vehicles point downwards I'm not so sure they are as much of a problem as some make them out to be.
Ford diesel engine needs replacing - rtj70
Quinny thanks for that especially:

"One of the parameters for Euro IV is that the catalytic converter has to be operational within a short length of time, so the ECU overfuels the engine when cold to heat the cat up faster"

Explains why on a good run I get decent MPG but around town nowhere near what I expected.

Of course we cannot buy new Euro III diesels anymore. And how would the lay person spot the difference between my Euro IV TDCi and a Euro III one???

If my car was privately purchased back in 2003 then Euro III at the time was cheaper on list price and did better MPG. But figure in a company car and Euro IV was cheaper monthly but possibly not as cheap as the better MPG Euro III would have been.
Ford diesel engine needs replacing - IanJohnson
When I changed mine (got a honda) there was no difference financially between Euro III and Euro IV for a company car driver because the list price was higher so you paid the same tax on each car!

Ford diesel engine needs replacing - cheddar
rtj, mine is 2002 so Euro III, yes I understand that Euro IV will be slightly less economical, also re EGR the design of the intake manifold was changed early in the life of the TDCi to move the EGR so as to allow the Durashift auto box to be fitted. AFAIK all TDCi's and X-Types built from around mid 2002 to date, 2.0 and 2.2 use the later manifold, mine was one of the last of the original type.
Ford diesel engine needs replacing - rtj70
Cheddar

Your comments plus Quinny100's make me wonder whether my two EGR failures and poorer MPG than expected is down to the re-design of the manifold and EuroIV. So for anything pre-2003 we might be okay. After 2003 to end 2005 you might not realise it's Euro III or IV and from 2006 all are Euro IV TDCi's.

So are we waiting for lots to have problems I wonder?
Ford diesel engine needs replacing - cheddar
So are we waiting for lots to have problems I wonder?

>>

I dont think so, as I have said there are loads of Mondeo TDCIs on the road and a few will be bound to have probs and those with probs will head to a site like this, the X-Type uses the same engines/components, we do not hear of X-Type diesel issues because there are far fewer on the road, likewise there are less CDT-is, less D-CATs etc etc.
Ford diesel engine needs replacing - Collos25
Totally agree the thousand upon thousands of satisfied Ford customers are highly unlikely to visit this site and praise their vehicle.Fuel figures are totaly dependant on how you drive and where you drive so are meaningless.This car in question had it been mine instead of all the bleating I would have had it running A1 by now at minimal cost, even if you exchanged the engine instead of repairing it I have seen upteen on E Bay in fact there are some at this moment .
Ford diesel engine needs replacing - rtj70
A colleague has a diesel X-Type. He's had more problems than any one I know including 6 fuel leaks in various parts of the injection system and one failed EGR valve. The only thing he's better off from is it's a Jag and the courtesy cars are Jag's too. He's had the dealer principles XJR, an XJ and a few X-types.

Cheddar you're right that there are so many fewer we don't hear about it the same. But hasn't it been mentioned before - isn't the engine in the Transit almost identical (made on the same production lines in Dagenham) and we don't hear much about them failing. And there's loads of them.