Diesel Diagnostics

Back to Forum

Post a Response

Ford Mondeo 2.0 TDCi 2002 - Hesitation at 2500 rpm #

Posted by Andy Small on November 30, 2010, 10:25 pm

Year of Manufacture *: 2002
Engine Size and Code *: 2.0 tdci
( Optional ) Scanner Used: ford ids
( Optional) Fault Codes: non

This vehicle seems to be pinking at lower rpm range, when cruising at about 2500 rpm or on overrun the engine jerks about with some small amount of blue/grey smoke, it sounds like its too advanced until boost then goes quiet and pulls like a train, there are no faults stored, the injectors have been tested & recoded, the egr valve cleaned & then blocked off, this vehicle has no maf sensor so a new map sensor has been tryed, fuel filter and a separate supply has been tryed, along with substitution of crank & cam sensors , fuel rail , high pressure pump, valve timing, dual mass flywheel.i have run out of things to try, any ideas welcome
Thanks Andy

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by Darren Cotton <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1876' width='330' height='300' border=0 style='border:none;'> on November 30, 2010, 10:49 pm, in reply to "Ford mondeo 2.0tdci hesitation 2500 rpm"
Darren Cotton

Andy,

When you say injectors have be tested,

What procedure did you use?

Darren

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by Andy Small <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5329' width='330' height='300' border=0 style='border:none;'> on November 30, 2010, 11:15 pm, in reply to "Re: Ford mondeo 2.0tdci hesitation 2500 rpm"
Andrew Small

i had the local delphi agent test the injectors & all passed with no problems

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by Darren Cotton <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1876' width='330' height='300' border=0 style='border:none;'> on December 1, 2010, 10:24 am, in reply to "Re: Ford mondeo 2.0tdci hesitation 2500 rpm"
Darren Cotton

Ok, what about inter cooler pipes, the one at the front on drivers side, that always splits.

put your hand round the back of it make sure its not split.

Darren

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by Andy small <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5329' width='330' height='300' border=0 style='border:none;'> on December 1, 2010, 9:26 pm, in reply to "Re: Ford mondeo 2.0tdci hesitation 2500 rpm"
Andrew Small

All boost pipes OK, you can get it to jerk about with the car stationary, bring rpm up to 2500 it starts to jump around like a misfire and you get blue/grey smoke, if you accelerate hard it jerks about on overrun also, there's a bit more to the story as follows, the car has had an engine change, the original engine suffered from bore damage due to gudgeon pin floating in con-rod, the vehicle was driven like this for about a month, eventually 3 hyd rockers failed and the engine was popping back through the intake, the engine was stripped and found to be non serviceable and a used engine was fitted, this engine suffered from the existing fault at 2500 rpm and had low compression on one cylinder when cold and it was decided to remove this engine and return to the supplier, a short engine was then purchased and the original cylinder head rebuilt and fitted back into the vehicle, the engine sounds fine but this problem still exists,the first engine fitted was complete and had its own injection system, so to sum it up two engines with two different injection systems fault still present, must be something that has been used with both engines or possible PCM/ICM fault maybe?
sorry for long post Andy

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by Dave Hill <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2783' width='330' height='300' border=0 style='border:none;'> on December 2, 2010, 8:34 pm, in reply to "Re: Ford mondeo 2.0tdci hesitation 2500 rpm"

This Mondeo sounds awful familiar. Is this somewhere in the east midlands?

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by Andy Small <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5329' width='330' height='300' border=0 style='border:none;'> on December 2, 2010, 9:32 pm, in reply to "Re: Ford mondeo 2.0tdci hesitation 2500 rpm"
Andrew Small

no this one is in west sussex, have you seen one like this before?

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by ian slattery <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1196' width='330' height='300' border=0 style='border:none;'> on December 2, 2010, 9:46 pm, in reply to "Re: Ford mondeo 2.0tdci hesitation 2500 rpm"

Do not know the year they changed but did early mondeo have a separate amplifier for the injectors. Also they had a pre supply pump in front of the o/s/r wheel they will run without it pumping.
Did not see the previous post about ICM but i think they use to give trouble
Sorry again getting the systems mixed up. It was the earlier di that had the pre supply pump not your tdci.

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by Dave Hill <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2783' width='330' height='300' border=0 style='border:none;'> on December 3, 2010, 9:02 am, in reply to "Re: Ford mondeo 2.0tdci hesitation 2500 rpm"

Yes Andy.

I had one from another garage that had a very similar history to it. Ultimately it turned out that the replacement engine had got the injectors from the original failed engine fitted. These injectors were incorrect for the second hand engine supplied.

If you ring your Ford parts dept & ask for an injector for a TDCI Mondeo (don’t be too specific) you will see that there are lots of choices available. My dealer stocks eight part numbers & although many look identical, some of them have different length nozzles. The nozzle protrusion into the combustion chamber can make a massive difference to how they run.

Trying to identify which injector is fitted (& more importantly, which ones should be fitted) to an engine supplied from a breaker, can be a headache to say the least.

The moral of the story is, to make sure that a second hand engine comes complete with injectors. If not then reject it!

HTH

Dave

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by Carl Ford <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1822' width='330' height='300' border=0 style='border:none;'> on December 3, 2010, 8:25 pm, in reply to "Re: Ford mondeo 2.0tdci hesitation 2500 rpm"
Carl Ford

I have had this before diagnosed faulty injectors for another garage then to find it back outside my workshop a week later with it worse than before and a mad taxi driver blaming me as the garage said I diagnosed the vehicle for him then to owe me another hours labour as his eBay injectors he got cheap and the other garage fitted nozzles were about half an inch longer
hth
carl

ps it wasn't to dificult for me to notice as I had the originals but how would you find out when you don't have the old ones and it's a 2nd hand engine?

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by paul goswell <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5240' width='330' height='300' border=0 style='border:none;'> on December 4, 2010, 2:56 pm, in reply to "Re: Ford mondeo 2.0tdci hesitation 2500 rpm"
Paul Goswell

i know this sounds daft but could it not be the tdc senor i did a clutch on one of these last week and had a similar problem as tdc sensor is on a adjustable bracket the air gap was to big and misfired at 2500rpm

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by Andy Small <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5329' width='330' height='300' border=0 style='border:none;'> on December 5, 2010, 9:34 pm, in reply to "Re: Ford mondeo 2.0tdci hesitation 2500 rpm"
Andrew Small

The Injectors i had tested were from the original engine, the cylinder head was reused but another short engine supplied, maybe different pistons ?? or the injectors were wrong in the first place, my local delphi test center says there are two different length nozzles and if the short ones are fitted it wont run but they are not sure if you put the long ones in place of short, i will try to find the correct part number for the vehicle first, the Tdc sensor is new and the installation procedure followed & checked, ford tis says to push tdc sensor till it touches the tooth on the flywheel and the airgap is now set due to small plastic pip on the end of the sensor?
thanks for posts still trying to sort it out.
Andy

Re: Ford mondeo 2.0tdci hesitation 2500 rpm

Posted by Dave Hill <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2783' width='330' height='300' border=0 style='border:none;'> on December 7, 2010, 6:10 am, in reply to "Re: Ford mondeo 2.0tdci hesitation 2500 rpm"
Dave Hill

Hi Andy

The small "pip" on the end of the sensor will only be on a new one. Once it has been fitted, the pip wears away. If you install a used one, then slide it in all the way & then just pull it back a Natts wotsit, you should be good.

Scope it if you have any doubts.

« Back to index

[ Diesel Diagnostics ]

Copyright © uk autotalk