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04mondeotdci
Hi everyone, I have been recommended to try this forum by a friend as I am having a nightmare with a 2004 Mondeo TDCI and ANY help, advice or suggestions would be much appreciated as im pulling my hair out.

-Itís a 2004 TDCI 115bhp originally but the engine blew

-It was changed to a 130bhp which was running perfectly in the donor car

-It sounds as if it is just about to start but wont actually go

-Flywheel, injectors (changed twice), injector pump all new also at correct pressure and its still not going.

-Taken to Ford and put on every piece of diagnostic machinery and not one fault code showing up so its obviously something that the diagnostic is missing or cannot detect.

-I have checked and double checked everything as much as I can and I am running out of money and patience and as some of you guys are very knowledgeable in mondeo engines if anyone has any idea as to what it might be, anything I could try or double check or have even encountered such a problem before and have some advice it would be much appreciated.

Thank you in advance, Shaun
digidash
[quote name='04mondeotdci' timestamp='1306570555' post='129388']
Hi everyone, I have been recommended to try this forum by a friend as I am having a nightmare with a 2004 Mondeo TDCI and ANY help, advice or suggestions would be much appreciated as im pulling my hair out.

-Itís a 2004 TDCI 115bhp originally but the engine blew

-It was changed to a 130bhp which was running perfectly in the donor car

-It sounds as if it is just about to start but wont actually go

-Flywheel, injectors (changed twice), injector pump all new also at correct pressure and its still not going.

-Taken to Ford and put on every piece of diagnostic machinery and not one fault code showing up so its obviously something that the diagnostic is missing or cannot detect.

-I have checked and double checked everything as much as I can and I am running out of money and patience and as some of you guys are very knowledgeable in mondeo engines if anyone has any idea as to what it might be, anything I could try or double check or have even encountered such a problem before and have some advice it would be much appreciated.

Thank you in advance, Shaun
[/quote]
mintalkin
which dmf was fitted a 130 or a 115 as the pick up for the crank sensor are different on the two flywheels.
digidash
had a 130 this week...been to 3 diesel specialists and ford. had engine transplant 3 sets injectors, 2 pumps, new cam and crank sensor, long story short the garage phoned me, updated ecu and injection drive module ......started first turn of key.this car also had no codes. i would be sly and phone ford back anonymous and ask if you bring a car for diagnostics will the £80 include ecu and modules updating. they will say yes if it needs it. once they say yes tell them you want to bring it back for this work doing for free. if they say it didnt need it or they did it ask for it in writing as the "repairing garage" wont believe you. my bet is they wont put it in writing and tell you to fetch it back down. i cant say 100% that is your problem without seeing the car but if it is no amount of work or money will solve your probs and ford should do it for free so this needs to be your first coarse of action, if ford techy is confused explain the injection system isnt operated by ecu but by a seperate module.tell them to go into..module programming>module reprogramming>idm, good luck steve
how does this work then
[quote name='04mondeotdci' timestamp='1306570555' post='129388']
Hi everyone, I have been recommended to try this forum by a friend as I am having a nightmare with a 2004 Mondeo TDCI and ANY help, advice or suggestions would be much appreciated as im pulling my hair out.

-Itís a 2004 TDCI 115bhp originally but the engine blew

-It was changed to a 130bhp which was running perfectly in the donor car

-It sounds as if it is just about to start but wont actually go

-Flywheel, injectors (changed twice), injector pump all new also at correct pressure and its still not going.

-Taken to Ford and put on every piece of diagnostic machinery and not one fault code showing up so its obviously something that the diagnostic is missing or cannot detect.

-I have checked and double checked everything as much as I can and I am running out of money and patience and as some of you guys are very knowledgeable in mondeo engines if anyone has any idea as to what it might be, anything I could try or double check or have even encountered such a problem before and have some advice it would be much appreciated.

Thank you in advance, Shaun
[/quote]
dude,mine had same trouble ,turned out to be crankcase sensor!,
04mondeotdci
Hi guys, Thanks for the advice last time its much appreciated.heres a quick update on the car.

Had the diagnostics expert out, he Re-programmed the injectors and its all tuned up correctly, its kicking and sounds like its about to stat a little more than before but still wont go!

Even though its stil not starting he noticed something he didnít before and says its quite unusual. With the ignition on, the engine management light is on as should be, when turning the key to start the engine kicks but wont fully start up. He tells me after a few attempted but failed starts the management light should go off automatically but its staying on. Does anyone have any knowledge or ideas on this? Is there a fuse in the ECU that could be gone? could the whole ECU be gone?

Any ideas right now would be useful as I am all out!

Again thanks for the replies last time ☺
digidash
i think 2 things. this car has a seperate injector drive module and the software version on this and the ecu needs updating. also many people code injectors as their physical number ie 1 2 3 4 when they should be done in firing order. if my attatchment works it would be worth showing it to whoever coded your injectors. i would find a good auto-electrician who has ford ids and they should do your updates and coding for £50. i got called out to one recently that had been to 2 diesel specialists up here and 1 in london...they fitted 2 new pumps and 12 injectors between them and just about every sensor on the engine. finally the garage called me and the car was running within the hour after being a non runner for over a year. without ids i feel you will end up going down the same road as this guy did so if you have already been to fords and paid them they need to finish the job you paid them for ie..perform software updates in ecu and injector drive module and code in the injectors. good luck and best wishes, steve
digidash
the file didnt attatch. please pm me your email address and a note re injector coding and ill send you the pdf, thanks steve
04mondeotdci
[quote name='digidash' timestamp='1307658889' post='131185']
the file didnt attatch. please pm me your email address and a note re injector coding and ill send you the pdf, thanks steve
[/quote]


Hi steve, thank you for your advice and quick replies, they are much appreciated and invaluable to me right now. My email is shaunbrennan@mail.com
04mondeotdci
Steve, Firstly thank you for all your help and the pdf it has been very helpful as after looking at the programming order i have noticed the order goes from the transmission>1.2.3.4 but im sure my auto electrician has programmed them in the order Transmission>4.3.2.1

Is the order in the diagrams definitely the order as my AE tells me and its uncommon for engines them to be programmed Transmission>1.2.3.4. If this is the case it could be the answer to my problem and i will get him out asap to re-programme them in the order of the diagram.

Thanks again for all your help Steve

Regards, Shaun


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