2.0 tdci - tdci engine cuts out

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Sat 7 May 2011 14:35
2.0 tdci - tdci engine cuts out - dh1983

Hi i am looking for some help, This is the third time its happened now, the garage are at a loss,

Last time they said it was frozen diesel in winter but now the same problem has happened again.

What happens - when driving along it struggles to accelerate in any gear and slows down to below 1k revs cuts out abut 500rpm. the glowplug light flashes once just as the engine stalls out,
( sometimes when driving it stutters like its about to stall or there isnt enough fuel but then its fixes itself again and is fine for another few thousand miles)

1st call nov 2010- AA got it fixed after an hour to trying to start but could didnt know what the problem was.
2nd call dec 2010 - Advised AA to tow to garage without start from ford garage so they could see if any fault codes came up, no fault we detected and they couldnt fine any other problems, they thought it was frozen fuel so they checked fuel lines and replaced the battery,
Today - called AA out and being towed to garage as we speak, i know its not frozen fuel in this weather.


any help would be great as i cant drive it anywhere without the worry of it cutting out

Edited by dh1983 on 07/05/2011 at 14:43

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Mon 9 May 2011 23:24
2.0 tdci - tdci engine cuts out - dh1983

the garage found a air blockage but could find the reason behind it, they re-bled the fuek lines, theyve told me to bring the car in whilst its stuttering too so they can find out the problem or see it happening.

Anyone have any idea?

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Tue 10 May 2011 00:40
2.0 tdci - tdci engine cuts out - ddr

Any smoke or other symptoms?

Has it got a genuine ford fuel filter, and have you tried changing it?

Ever feel a vacuum in the tank when opening the filler cap?

Sure it hasn't got a 'tuning' box fitted?

Seems hard to beleive that no codes are being stored...

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Tue 10 May 2011 13:20
2.0 tdci - tdci engine cuts out - dh1983

there is no smoke on start up or driving that i notice or anyone following me has said,

it had a full ford major service in nov, as the stuttering they thought was a dirty fuel filter, that didn slove in for a few weeks though,

I hear a hiss noise when i open the fuel cap is that normal?

ive never fitted a tuning box to the car surely it would fail on MOT from what ive read though with one of them? I know thats what the AA guy said too, he plugged his wee device into the car and its came back to no fuel pressure i think so he rebled the lines but it was 3/4 of a tank,

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Tue 10 May 2011 13:30
2.0 tdci - tdci engine cuts out - ddr

I hear a hiss noise when i open the fuel cap is that normal?

Not sure - i never hear it. Might be worth looking for the fuel tank breather pipe and making sure it's not blocked. Also next time it happens, try opening the fuel cap and see if that helps restart. Worth a try. Either that or your fuel pump's had it, which isn't cheap.


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Tue 10 May 2011 15:32
2.0 tdci - tdci engine cuts out - Collos25
I think your onto something there the tank should not be pressurised.
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Tue 10 May 2011 15:48
2.0 tdci - tdci engine cuts out - ddr

Just read that the vent is actually intergrated into the filler cap. Get a new cap from ebay perhaps, or dissasemble and find out what's wrong with it.

More clues here:

http://www.rac.co.uk/forum/showthread.php?1090-Help-with-ford-mondeo-please!!!/page4

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Tue 10 May 2011 19:28
2.0 tdci - tdci engine cuts out - dh1983
I think your onto something there the tank should not be pressurised.

my mistake there isnt a hidding noise coming from the filler cap when opened!

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Tue 10 May 2011 23:01
2.0 tdci - tdci engine cuts out - R2-CMax

Could be the EGR valve jamming open - particularly if it happens when you're trying to accelarate - very hot exhaust gas is pulled back into the front of the engine, so the engine goes into self-preservation mode to avoid something getting fried.

When it happened to me, the engine would continue to idle in neutral, but not rev at all. Stop & restart will provide a temporary fix. Not sure why there is no error code being stored - the flashing engine light says that one is being committed to memory.

This is was a reasonably common issue on 2L TDCi engines, particularly fitted to early C-Max and Focus II (53-05 plates), but I'm sure can still happen on more recent cars.

If this is the cause, it's really a dealer/specialist job as the valve needs to be calibrated by a man with a laptop.

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Wed 1 Jun 2011 17:09
2.0 tdci - tdci engine cuts out - dh1983

Almost a month later and still having problems, they has said the fuel sender unit needs to be replaced and would cost £470 plus vat. what does this unit do? also could this have been the problem ive had for the past year and would it cause the car

1- to stutter whilst driving like it wasnt getting fuel

2 - stall when driving.

if so would i have grounds to claim it to be fixed free of charge as this stutteruing started in june lastyear whilst it was in warranty!

Edited by dh1983 on 01/06/2011 at 17:15

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