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B05CH3R

2006 Ford Mondeo Zetec TDCi 130ps, N7BB engine.

replaced egr valve,map sensor, intercooler to egr pipe and turbocharger,full service 2k miles ago.

(believed to be) "black" smoke under acceleration and in turbo lag range heavy acceleration alot, turbocharger vanes haves seized in under a month of new turbo being fitted, being sent for repair.

help!! any ideas.

 

stooge75

Have you checked all pipes/hoses for splits? Is maf sensor working 100%(not map).
Try blanking EGR or disconnect vacuum pipe on top of it. It might throw a p0401 code but wont put it into limp mode. See how your smoke issue is then?
Ps did you replace EGR with a brand new one?

ps:didnt realise your turbo had seized at this point lol

B05CH3R

all hoses check ok, egr was brand new and only fault code was P132b which is turbo performance problem, maf seemed to check out ok on live data but cant fully remember 

stooge75

did you say its been sent for repair now? a god diesel specialist is needed mate as its no good guessing.they'll find out whether its the actuator thats faulty or another fuelling/elec problem. tthere's just too many things that can cause your symptoms & is easier to solve if the mechanic has the right kit & knows what he's doing.

B05CH3R

yeah turbo was brand new/reconditioned unit, on the 02/10/2013 by turbo solutions and the actuator done a month before by ecu testing, slight problem is i am a mechanic but dont have right  ford oe spec kit

stooge75

If you're a mechanic & cant solve this,I'd suggest that you take your car to a good diesel specialist. You're not going to find out by guessing as your turbo is electricaly activated,& there's too many things it can be,whereas if you take it to someone who knows these systems inside out,you WILL get it sorted sooner rather than later,and you'll save £££ in the long run.The reason your turbo is seized again is probably due to an underlying fault that needs to be rectified before advancing any further.

also,when you undo the clip on the actuator arm,does it move back & forwards at all?

someone might be able to confirm whether a new actuator needs to be calibrated to your refurb'd turbo(just in case,was it done?do you know?

B05CH3R

nope the variable vanes have seized, the actual bearing, feels loose on exhaust side, but its the vanes that have gone, problem i have is our local ford specialist on guernsey are not at all helpful as i have had to do all diagnostic and research myself, no help whatsoever, and being on the island do not have good ford diesel specialist to hand, if you could recomend a specialist close to southern ports would be a great help 

stooge75

sorry mate im in scotland. what about putting an ad on gumtree for a diesel specialist close to you.

who installed the actuator/turbo? yourself?

B05CH3R

yeah all myself 

stooge75

ok. just been told the actuator doesnt need calibrating to another turbo. why wont your local Ford dealer sort it? you're saying theyre not helpful. but can they sort it? i presume theyd be able to. personally I wouldnt want a bill from a ford dealership for this kinda thing but when your staying where you are,well what can i say. Im at a loss mate,dont know what to tell you. some of the other guys might be able to point you in right direction

zoy

jump on a ferry in limp mode!

jeebowhite

As you know most the time black smoke is over fuel and under breathing, I had the same issue on my car and had to replace the turbo intercooler pipe. It was a thin hairline crack that did it, barely noticeable to the eye, but you could feel it when the engine was running. Have you checked for something similar?

 

As for the EGR I would suggest blank it!

B05CH3R

can't hear any leaks will double check the pipes whilst car is off road, injectors at 120 thousand miles possibility? i want no lights on, so isit true blanking electronic egr cause engine light, car is on ferry December so might pop to a useful ford dealer whilst away. i went to my local ford dealer many times with fault codes and full vehicle history asking them to point me in right direction, they said they dont deal with many mondeo's and especially at that sort of mileage, being on an island stuck to 35 everywhere, and alot of stop starting they dont have a clue about high mileage, and long running engine problems.

jeebowhite

Some engines have a light temporarily, Stef just trained his car after leaving it for weeks to ignore the EGR Blank. the light went out, whether that is the car finally accepting that its not going to be listened to, or what I dont know. It seems to be sporadic as to what it does and when.

 

With the leaks you dont really hear it, you need to run your hand down the side of the pipes and feel for a blowout from the pipe.

 

Check my guide in my signature for replacing a cracked intercooler pipe. that will help you to understand what I mean.

stooge75

jeebo where abouts on intercooler was the crack?

jeebowhite

it was literally alongside and just a tiny bit above the bracket.

 

Take a look at the guide in my signature, there is a picture there showing it :)

B05CH3R

all pipes ok no splits, cracks or holes

stooge75

could be a lot of things mate. cant you somehow get it to a diesel specialist or good mechanic on mainland that really knows what he's doing? any really good mechanic would hook it up & start reading & testing components/sensors,& maybe a leak-back test on injectors.as your injectors are on the same mileage as mines when they decided to pack up.these diesel motors are complex when it comes to fault finding if you dont have the proper VCM to interpret the data.

hows your diesel filter? renewed that?

B05CH3R

full service including all filters, done 2 thou miles ago, still awaiting good recomendation on a decent ford diesel garage.

mick85
Check inter cooler not damaged or cracked
B05CH3R

intercooler all looks okay no sign of cracking or damage

mick85
So wats ur issue black smoke under acceleration
B05CH3R

yeah, which has caused the vanes to seize a recon turbo in under a month, poss injectors?

stooge75

read from post no1,it'll give you some idea mick. he's had a few issues & i think theyre all connected.

B05CH3R

the garage i work at specialize in german manufacturers hence the help required here

stooge75

Id be looking to see if my MAP/MAF sensors are working ok 1st,along with no leaks in pipes/IC etc.

and really,the only 100% sure way is by looking at her running on live data.It'll tell ya if its getting enough map pressure,fuel rail pressure,etc. then a leak back test off your injectors. any competent diesel specialist would find the fault in an hour most likely. there's not a lot of stuff really that make engines work properly,& all good diesel specialists know the proper routine for finding them. ie: fuel,then air,then injectors,then elecs etc(maybe not in that order).its a process of elimination,but pointless if you havent got the right equipment & knowledge

B05CH3R

only parts i havent had problems with or replace are maf injectors and timing

stooge75

have you taken the MAF sensor out & cleaned with contact cleaner?(dont touch the wire filament with anything)

mick85
Couple question ur mondeo older one is turbo vacuum or electronic black smoke usually fuel or turbo hoses ripped is all pipes expanding when u rev at idle have u access to leak off test or decent diagnostic tester
stooge75

its electronic actuator(he had it replaced along with refurb'd turbo)

FOCA

2006 Ford Mondeo Zetec TDCi 130ps, N7BB engine.

replaced egr valve,map sensor, intercooler to egr pipe and turbocharger,full service 2k miles ago.

(believed to be) "black" smoke under acceleration and in turbo lag range heavy acceleration alot, turbocharger vanes haves seized in under a month of new turbo being fitted, being sent for repair.

help!! any ideas.

 

Sorry to hear you are having trouble

 

What part of the turbo is new? the cartrige, the manifold (the VNT mech is in the maniflod) the actuator? what part got damaged, the actuator due to siezed vanes - be specific "the turbo/ new turbo" could mean lots of things/ components  

 

Have you read the codes? do you have a compatible code reader? (Ford has its own protocols, readers can have compatibility issues)

 

Unless you have very deep pockets i would stay away from main Ford dealers (i worked for one) and "diesel specialists" - they will be replacing parts left, right and centre, probably the 1st thing they will advise is new injectors (thats the way a "diesel specialist" thinks - injectors etc) before you know it you will have spent twice what the car is worth on parts

 

Look at the value of the car, then what has already been replaced (has the DMF, clutch and CSC been done?) and how much it will cost to fix,

 

probably best to fix it yourself - aquire a code reader and take it from there

 

 You can always stick a solid, stainless steel EGR blanking plate on the car (about £4)   

stooge75

"thats the way they think?" my,you're presuming!. 

Blurredfocus
Have you checked you oil feed to the turbo for blockages carbon build up?


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