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Z3 MON
Hey guys,

Just brought a 2004 2.0l tdci. It still pulls really well but has a lumpy idle and the car actually wobbles a bit. It's got a bit better. I bought it yesterday and it was sat for some time, no smoke or anything.

Also have a issue with the rear drivers side brake light staying on with the side lights so the full circle is lit all the time rather than bottom half only when not breaking??

Any ideas??

Cheers
Dave
Z3 MON
just to re iterate its every time i stop and am stationary and its intermitant.
Z3 MON
just to re iterate its every time i stop and am stationary and its intermitant.
mintalkin
it could be a gummed up or stuck EGR valve, these can be removed and cleaned, as for the brake light check for any damage to the wiring or fitment.
Z3 MON
Will do :) is the valve to the right of the turbo as you look at the engine???
Z3 MON
Quick update, started it to go home, as usual started on the first turn easily. No effort. However we did notice a rather large plume of slightly black smoke (not blue) it didn't smell like oil but just like a stronger smell of the usual emmisions. The engine is rather noise but it is missing the plastic engine cover so I put it down to that.

I'm gona try and strip off the valve and clean it out this weekend and see where we go from there.

It doesn't seem to be getting any better from a few dual carriageway blasts, the weird think is its so nice and smooth to drive. I just don't get it.

Thanks

Dave
pragmatix
This may help you do a search for ford wiki there is a detailed guid to EGR cleaning on there, sorry not allowed to post a link
Z3 MON
That guide on Ford wiki is ideal. Is this a common problem on the mondeo??
pragmatix
[quote name='Z3 MON' timestamp='1328213507' post='164465']
That guide on Ford wiki is ideal. Is this a common problem on the mondeo??
[/quote]

Common to all cars that have an EGR, a very dodgy soloution to a problem that doesnt really exist. Who ever thought that putting burnt exhust gases back into an engine is an idiot, dont get me started on catalitic converters, they cause more polloution than the cure, the lean burn engine was the way forward but the cat was thought as a cheaper (short term ) soloution, do a search for lean burn engines it will through up lots of reading.
Sorry rant over
1djspikey
[quote name='Z3 MON' timestamp='1328213507' post='164465']
That guide on Ford wiki is ideal. Is this a common problem on the mondeo??
[/quote]

yeah it is david most garages go for the EGR valve like they did on mine but that problem as been sorted and it was`nt the cause next plan is to get my injectors tested as one of them as a slight little leak around it i hope this is the problem as its doing my nut ive change fuel pump solenoid wich i was told to do after going to ford for a code reading test and the problem still went on so it just leaves the injectors or fuel pump its self these cars are lovely when working right :wacko:

john
1djspikey
[quote name='pragmatix' timestamp='1328214628' post='164470']
Common to all cars that have an EGR, a very dodgy soloution to a problem that doesnt really exist. Who ever thought that putting burnt exhust gases back into an engine is an idiot, dont get me started on catalitic converters, they cause more polloution than the cure, the lean burn engine was the way forward but the cat was thought as a cheaper (short term ) soloution, do a search for lean burn engines it will through up lots of reading.
Sorry rant over
[/quote]

yeah i got agree with pete EGR valves are the most stuipid idea its just a money maker i think plus most people have them blanked off so they don`t cause more problems in the future .

john
Z3 MON
Thought so. Am I right in saying that the valve does in the same place as a wastegate on a scooby or is the wastegate/dumpvalve the same as a egr valve ??,
pragmatix
[quote name='1djspikey' timestamp='1328215590' post='164472']
them blanked off so they don`t cause more problems in the future .

john
[/quote]

That causes as many probs as it cures
Z3 MON
[quote name='1djspikey' timestamp='1328214851' post='164471']


yeah it is david most garages go for the EGR valve like they did on mine but that problem as been sorted and it was`nt the cause next plan is to get my injectors tested as one of them as a slight little leak around it i hope this is the problem as its doing my nut ive change fuel pump solenoid wich i was told to do after going to ford for a code reading test and the problem still went on so it just leaves the injectors or fuel pump its self these cars are lovely when working right :wacko:

john
[/quote]

Mate that's getting, I really hope mine is not injection related. What happens to the injectors???
pragmatix
[quote name='Z3 MON' timestamp='1328216207' post='164475']
Thought so. Am I right in saying that the valve does in the same place as a wastegate on a scooby or is the wastegate/dumpvalve the same as a egr valve ??,
[/quote]

No not the same thing at all wastegates/dump valves stop a turbo over presurising a EGR ( exhaust gas recirculating ) valve just sends a portion of the exhaust gases back into the inlet manifold
Z3 MON
[quote name='pragmatix' timestamp='1328216263' post='164476']


That causes as many probs as it cures
[/quote]

What problems ??
pragmatix
[quote name='Z3 MON' timestamp='1328216579' post='164480']
What problems ??
[/quote]

ECU warnings hesitant running, etc, all its suposed to cure, depends on the motor a real black art it appears
Z3 MON
wonderfull lol
Z3 MON
Sorted the rear lighting issues out tonight, some very questionable accident repair work. Also a filament had broken in the stop/tail bulb and shorted aswell. So after replacing a total of 6 bulbs and some re wiring, the rear light all work.

Also got my radio code today aswell.

Just reach 112 miles and suddenly the lumpy idle is starting to go.

Got some BG244 on the way an if its not to snowy tomorow ill crack at taking the egr valve off...

Cheers
Dave
pragmatix
Gald your getting things sorted
Z3 MON
Me to, its sounding rather tappety though
pragmatix
Tappets are hydraulic, so an oil change might help
Z3 MON
Bought it Wednesday, still havnt checked oil :s although service book says last service 79,000 its now on 82,000 and says the next one is not due till 90,000. Will check oil tomorow, its snowing to heavy now lol.
Z3 MON
Update: so today my dad sorted all the wiring out for the rear lights. I took the egr out, the main bit wasn't to bad but the little bit was bad, the pipe the comes out the bottom seemed to have diesel/oil on it but smelt of nothing. The oil was a down a litre. Topped that up. Started her up and she was great for a couple minutes and has now started hunting. I am thinking give it 100 miles and see where it goes. If not I've got some BG244 on its way, failing that ill reset the ecu, so frustrating as she runs soo smooth.

Dave
Z3 MON
BG244 came this morning. Will chuck it in tonight with some diesel and leave it to idle for 15 minutes and see how it goes. Will it matter that I used redex about 120 miles ago ??

Cheers

Dave
Stoney871
I personally wouldn't use redex as it strips lubricant from the engine.
Shouldn't be a problem running it and the BG244 at the same time.
Z3 MON
Yer I know that now lol. I really hope I can sort out the idle issue. It's the only thing letting the car down.
Z3 MON
right so this is what she is doing now:

Video (sound required):
[url="http://s171.photobucket.com/albums/u300/zemonmotorsport/?action=view&current=VIDEO0007.mp4"]http://s171.photobucket.com/albums/u300/zemonmotorsport/?action=view&current=VIDEO0007.mp4[/url]


so i cleaned the egr valve but it wasnt that bad, once re fitted and oil topped up she ran fine on idle for about 5 minutes.

egr valve:

this is the only bit which was badly clogged up:
[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/IMAG0716.jpg[/img]

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/IMAG0715.jpg[/img]

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/IMAG0714.jpg[/img]

and the beast:

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/IMAG0718.jpg[/img]

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/IMAG0719.jpg[/img]

thanks

Dave
Z3 MON
anyone>?
Z3 MON
Just been for a short motorway blast and was waiting for about 15 minutes on idle and the idle was slowly getting a lot better and then drove a bit more and it went back to being shit again. Ahhh no idea what the fudge is causing this pants idle.
Z3 MON
The missus is doing some motorway miles today so we shall see how it goes. I have noticed though when its standing for a few moments there is droplets of black liquid (possible oil) coming from the very front (possibly rad) has a quick look and i cant see anything as there is a cover on the bottom of the car so i have no idea where its coming from.

Really starting to wish i hadnt bought this car as its one thing after another :(

i also noticed last night that when looking at the boot from inside the car there is a massive (couple inch) gap between the rubbers on the boot lid and the chassis (bad accident repair) really anoyed now :(

as long as i can get her running properly then at least i can worry about the cosmetic side later im just soo anoyed at the moment.

so at the moment we have a possible small leak (im hopping a pipe) and its hunting fairly badly (as per previous video)

soooo pissed off........

Dave
pragmatix
Could be a leaking intercooler or intercooler pipe
Z3 MON
yer thats what i was thinking mate. Just had a look on ebay, the pipe is the same bloody price as the intercooler?? lol

never mind, just want to get it all sorted now and then ill be happy and will be able to justify buying some DMB graphics.

i have so many plans but i just want to get her running properly first.
Z3 MON
Ok now the symptoms have changed. it still hunts but now only seems to be once its warmed up? im thinking either the BG244 has done its job and there is another issue or this is the BG244 still working its way through and is slowly fixing it.

Now we have done over 100 miles since i put it in but the tank was half full when i p-ut it in and then i topped it up with another quater tank. its now at half a tank again.

The other thing is MPG. I dont have any figures but the car has had a tank and a half since we owned it and is now on half, so that 1 tank used to 260miles? surley this is not right?

Dave
s.jsutton
No mate definitely not right.
Mine does about 400 round town and 500 on a run and I have a heavy right foot.

regards
simon
Z3 MON
Could this be a coil pack issue???
s.jsutton
Think you'l find that there is no coil on a diesel - works on compression to fire the diesel, not like the spark on a petrol.

regards
simon
Z3 MON
doh, so used to petrols.

I went ahead and bought this:
[url="http://www.ebay.co.uk/itm/160720137363?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649"]http://www.ebay.co.uk/itm/160720137363?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649[/url]

should be here tomorow so ill run it on the modeo and see what it throws up. I Figure its better than just trying to stab in the dark, i do have that tingly feeling of knowing its going to throw up injector knock tolerence, but theres always hope lol.

I will be doing a full service on payday aswell, as despite the service history stating it was service 3,000 miles ago, judging by the state of the air filter - i doubt it. it will also have a new fuel filter although i am a bit worried about changing this incase she then doesnt start (i will top it up with new diesel first, but have heard cases of even when this is done it still wont start :S )

Ill let you know what codes it throws up if any and ill also let you know if this software/lead is any good.

Cheers

Dave
pragmatix
Keep us posted on how well it works
Z3 MON
Will do.

By the way here is what I have so far:
Idle rougher when warm.
Idled well in snowy conditions.
No warning lights.
Knocking noise on idle (sounds like big end kind of noise).
Runs smooth once warm except on idle.
Egr valve cleaned - ran better for 5 minutes.
BG244 used - more powerful than before but only marginly.
No clutch slip
Starts first time every time.
Tappety when cold.
No diesel round injectors.
No smoke.

I am also buying a egr blank valve just to see.
Z3 MON
Me, The missus and the boy just been out for a drive. No Set destination, No time limit, no reason........just a good old fashioned drive.

And boy did i buy the right car :)

If you hit that rev range right, then that turbo really gives it some....

Now i want to fix the idle so that it runs better and so she doesnt get damaged, rather than because its anoying me lol.

Its the first real "drive" ive had with her(the mondeo not the missus lol)

Just though id share :)
Z3 MON
Just had the weirdest thing happen, just drove 2 miles up road and the fuel gauge between half and quater, stopped turned off, got out, turned on fuel gauge in same position, drove another 3/4 of a mile and then i stalled it at the lights and then turned back on and bam its at 0 petrol with the red light on??????

also does anyone know where the fault code reader plugs in on the mk3?

cheers

dave
Z3 MON
[b]Update time:[/b]

so the symptoms:

[url="http://s171.photobucket.com/albums/u300/zemonmotorsport/?action=view&current=VIDEO0008.mp4"][img]http://i171.photobucket.com/albums/u300/zemonmotorsport/th_VIDEO0008.jpg[/img][/url]

Rough idle
Tappety noise from engine
oil/diesel smell inside cabin
down on power
bit smokey when floored
poor mpg
Woooosh noise on boost

still started first time every time, no warning lights,

So firstly: the smokey issue and down on power was resolved by removing the EGR valve and cleaning it and refitting it along with running good quality fuel and a tub of BG244 through the fuel system. (we also noticed an improvement on the MPG a little)

But after that i had no idea what was happening regarding eveything else so the best we could do was say it could be this or could be that untill we could get it plugged into a diagnostic machine. so i thought instead of trying to gusse ill by a OBDII lead of ebay. so i did that and plugged it in this morning and got this:

On Ide:

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/idlemetricdash.jpg[/img]

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/idle1.jpg[/img]

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/idle_flowandpressure.jpg[/img]

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/idle_temps.jpg[/img]

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/idle_tests.jpg[/img]

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/datalogger.jpg[/img]

and then i done it at 2000 RPM:

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/2000rpm_genraldata.jpg[/img]

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/2000rpm_flowandpressure.jpg[/img]

[img]http://i171.photobucket.com/albums/u300/zemonmotorsport/2000rpm_temps.jpg[/img]


Basically no fault codes and nothing wrong. so i was like great what a waste of time and money buying this lead snd waiting for it to arrive.

So i decided it must be an exhaust leak, it sounds so loud like a tractor, it has to be.

so jumped in the car and went to my dads to get my tools and axel stands an what not, but he wasnt in nor was he answering his phone.... great i thought, so i decided to go to quick fit and luckly enough got some free time on a ramp, although i wasnt allowed to operate the ramp or work on the car only look(insurance reasons). so i told the bloke i think there is an exhaust leak so on goes the car and up goes the ramp and he covers the end of the exhaust but clearly there is no leak. so we walk to the front and shine his torch up there and bam. there it is making all this noise............ the belt and tensioner for the AC and power steering. bouncing all over the place. so i thought thats great but what about the smell in the car and the whoosh noise. and then right there in the corner of my eye was a boost pipe smothered in oil.

so on monday i shall be calling ford to see what they can do about the belt ~(seeing as they are aware of the issue and have a new part to replace it i expect they will do it cheaper than most other places as effectivley it was a recall due to using a spring thats not suitable for the job)
and also on pay day ill order a new boost pipe. in the mean time the bloke tightened up the assembly for me and got rid of the awfull noise ...for about 20 minutes lol but i knew it was only a quick fix. and he wouldnt let me give him for than £4 for it. ..... result lol

sooooo there you guys.......

ill keep you update regarding when parts get replaced ect to confirm if these were the issues...
pragmatix
See post 32, allways check the basics
Z3 MON
[quote name='pragmatix' timestamp='1329591434' post='167477']
See post 32, allways check the basics
[/quote]

indeed, but from above you would not have a clue about this leak lol
pragmatix
Just shows diagnostics dont show everything
Z3 MON
indeed,
Z3 MON
Ford want £350ish fitted for the crank pulley and kit ect. :angry: :o
Z3 MON
Now there saying 475 :(
s.jsutton
Would you like me to get a price from my mate?
His garage is in Twickenaham, so not too far from you.
If so give me your exact model and reg.

regards
Simon


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