[Closed] Car help re - smoke!

Sounds like something to do with the turbo if its happening at 1800 RPM, only when you boot it rather than gently accelerating?

Sounds like engine flush has either dislodged some muck or something. Any other symptoms? Searched Pistonheads?

http://www.fordownersclub.com/forums/index.php?showtopic=17444

seems to be identical

hmmm, possibly a blocked engine breather from as above (engine flush dis-lodging $hite) take it back to the garage and see waht they say, or take it to another garage and ask what they think, then you can do some finger pointing. If the incorrect oil is used it can cause the valve to clog up, on zetec's anyway!!, saying that is your TDCi a zetec, i think it could be..

it says in the OP

TDCI is Duratorq, IIRC Zetec is trim level only

It's the EGR valve located front right of the car. It clogs up and needs cleaning which is a mucky job. Step by step guides are on the Mondeo [url= http://fordwiki.co.uk/index.php?title=EGR_Valve_and_Inlet_Manifold_Clearout_TDCi ]forum[/url]

craig - how can you be so sure? (was my initial thought also btw)

Take it back to whoever serviced it rob! It could be a number of things but if it's not right they should be straight on to it for you.

Does it have normal power or is it down?

its down i think - slightly sluggish not pulling me back into the seat

I've had it with both my Mondeo's It feels like the car is really sluggish then takes off around 1900rpm which is when the turbo is creating peak torque. The cars that get the fault most are those that do a lot of town driving as opposed to those that are on the motorways mainly. A good ragging every now and again clears it out of the EGR valve.
If it feels like the turbo isn't coming in and lack of power regardless of revs it would be a split in the charge pipe coming up intercooler to the EGR pipe. It costs about £55 for a new from Ford.If you're anywhere near Leeds I have a spare in the garage.

I cleaned the EGR valve in our 2003 TDCI Mondeo, it wasn't jerky but did clear up some hesitation and flat spots. Pretty easy job but stay about 10 metres from the house, and change your shoes before going inside as I spent longer cleaning the carpet than I did cleaning the EGR 🙂

Zetec is indeed just the trim level, a bit confusing as the name used to be used for one of their petrol engines, but not anymore.

Will contact the garage tomorrow

Just check that the air hoses from airbox to engine are connected, its very common on Ford diesels for them to come off (ie jubilee clip not done up or not pushed on far enough). This not only upsets all the sensors but produces masses of black smoke.

What mondeo has ever pulled anyone into their seat?? 😆

Never very keen on anyone putting "flushing" anything into a car. A well maintained engine should never need flushing with anything. Regardless, that has now to do with this problem!

What mondeo has ever pulled anyone into their seat??

[img] [/img]

Colour of smoke?

From Honest John...

"TDCI 130bhp engine may suffer from starting problems and uneven idling, may misfire between 1,800 and 2,000rpm, may sometimes cut out and may not be particularly economical with 42.5 mpg fairly typical. Partially cured by a an ECU software download, but head and injectors have also been modified on later cars.
Also reports of the TDCI smoking and of high oil consumption, which may be turbo oil seals. "

http://www.honestjohn.co.uk/carbycar/ford/mondeo-iii-2000/?section=bad

Had the same on my Mondeo recently

Split turbo pipe

Smoke is black. In the garage on Wednesday. He reckons split pipe

Ha ha - found the source of the problem!
[img] [/img]

The red cross is the start of a 3" split that goes down beyond the Power steering fluid pipe - this "SHOULD" be secured by a ziptie (circled) but it has been cut and not replaced 🙁

Red cross?

Yeh the red cross took me a couple of minutes to find...worse than a 'where's wally' picture 🙂

look right from"2a" that is stamped on a metal flat.

BTW - is it safe to drive??

[img] [/img]

bit clearer

Should be safe to drive, but you'll probably be getting significant over-fuelling which you don't want on an ongoing basis.

only to work and then garage - 24 miles all in

I am in teh RAC - would it be a job they could do? i.e. is it a specialist or stock piece of hose? Any bodges to repair it for the journey to work tomorrow? Averaging 25ish mpg today 🙁

You can do it yourself. EGR valve is held on by 4 bolts and a circlip. Remove the electrical plug if fitted and the thin rubber pipe, remove the nuts from the horizontal metal pipe then undo the 2 bolts from that are holding it in place attached to the black plastic inlet manifold. You may need a deep socket or extension bar to get to these two. Loosen the circlip on the thick rubber pipe (the one thats split)you'll now be able to remove the EGR from the metal pipe and off the rubber pipe. One other circlip holds the pipe in place which can be reached from under the car in the front bottom right corner. It's attached to an S shaped metal pipe. Remove the pipe from the top of the car, refitting is the reverse a little silicon spray makes fitting the pipe easy. When attaching the EGR to the manifold there should be a rubber seal where it attaches to the manifold. The whole job takes about 30 minutes to do.
The pipe can be repaired to keep you going by wrapping the split in duct tape then reinforcing it with 3 or 4 zipties.

I know i can do it but have no time as at work at half seven tomorrow AM