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Tdci Problem.help!!!


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#1 B05CH3R

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Posted 11 November 2013 - 03:13 PM

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.

 



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#2 stooge75

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Posted 11 November 2013 - 04:48 PM

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



#3 B05CH3R

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Posted 11 November 2013 - 07:04 PM

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 



#4 stooge75

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Posted 11 November 2013 - 07:36 PM

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.



#5 B05CH3R

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Posted 11 November 2013 - 08:25 PM

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



#6 stooge75

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Posted 11 November 2013 - 08:43 PM

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?



#7 B05CH3R

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Posted 11 November 2013 - 09:04 PM

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 



#8 stooge75

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Posted 11 November 2013 - 09:16 PM

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?



#9 B05CH3R

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Posted 11 November 2013 - 09:28 PM

yeah all myself 



#10 stooge75

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Posted 11 November 2013 - 09:54 PM

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



#11 zoy

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Posted 13 November 2013 - 12:19 AM

jump on a ferry in limp mode!



#12 jeebowhite

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Posted 13 November 2013 - 09:16 AM

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!



#13 B05CH3R

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Posted 14 November 2013 - 06:10 PM

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.



#14 jeebowhite

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Posted 15 November 2013 - 11:16 AM

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.



#15 stooge75

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Posted 15 November 2013 - 01:00 PM

jeebo where abouts on intercooler was the crack?



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