Working On The Mondeo With Photos

[Ford Loyalty MK3]

Keeping it plain and simple, hopefully this will help me find the fault as well as others that may have the same problem.

1 When I first got the car the mondeo was great, gave it a service and ran even better

2 Glow plug warning light came on, first thought glow plugs so they were replaced

3 When putting your footdown all the way to overtake someone glow plug warning light came on and the mondeo was on limp home mode, turn the car off start again and glow plug warning light gone till doing over 70mph again.

4 Pressure release valve was changed, still no inprvement with the lack of power issure.

5 Mondeo serviced again after 3 months, air filter badly clogged cleaning housing and off I go

6 fuel filter was replaced, took a while to get it starting but otherwise ran very well.

6 oil change with oil addertive to reduce tappet noise

7 2 weeks after leaving my car overnight it was really cold, glow plug warning light comes on and flashes all the time.

8 car wouldn't start, lots of smoke and strugling to start/ cold starting

9 engine warms up drives normal, but with lack of power very much like turbo lag

10 mondeo in the garage, fuel injector test shows pressure is different on all injectors, could be caused by air to fuel ratio not being correct, split hose, blocked pipes, egr etc

Some pics of work done on the car

[Ford Loyalty MK3]

First job I did was remove the inlet manifold, !Removed! coverd in crap which didn';t help the car breath as you can't tell with the pics, used carb cleaner and some sand paper and gave them a real good clean.

Hoses checked and made sure they were tight, so far everything appers normal, but you can't very well from the top, so might be a idea to remove the front bumper and remove the intercooler for closer inspection.

air filter and housing again coverd crap and gave them a real good clean as well, hopefully that should inprove the cars performance.

Egr valve removed, coverd in carbon and hopefully a dip of acid should free the valve or plunger ans should do the job.

[FOCA]

You have a Euro3 Mondeo mk3 TDCI with rear mounted EGR and variable vane turbo - probably a 130PS

Your EGR valve can be blanked with no problem, it will not cause the engine management light to go on or cause an MOT failure etc, it will reduce the amount of smoke and stop the inlet from being contaminated with carbon, best to use a solid, stainless steel plate, you can fit it to the "inlet" side of the EGR valve

The hoses that are bad for splitting are in picture 5

Your (main) problem may be that your VNT (variable nozzle turbo) vanes are coking up and sticking, it controls the boost pressure level and affects lag too

[Ford Loyalty MK3]

Is that the hose that runs from the turbo to the intercooler you mean? Trying to gain acess to it, its very akward I can tell you. If it still doesn't run right then I'll put a video up, it could be a timing issure as well, diesels can still run with the injector timing out.