Engine Cutting Out (Mk3 Tdci)

[mch1991]

Hello,

I've had my 2003 Ford Mondeo Zetec for a while now, and to be honest, apart from some problems regarding the glowplug light coming on at random times, the car has done very well the last 1,000 miles. The car feels very good on the road, and the TDCi engine pulls very nicely.

However, over the past week and a half, I've noticed a slight issue in regards to the engine just cutting out. Here's an example;

Today, I was driving in traffic (slow moving stop start), set off normally in 1st, built a bit of speed before having to stop (was in 1st still), pressed the clutch right in to let to car roll a little bit before stopping. As I pressed the clutch in, I noticed the revs went up to about 1,500 RPM, then below 1,000 RPM before dropping to about 500 and cutting out. This isn't the first time this has happened. It feels as if the car is trying to find the idle RPM however just cuts out.

Also, the glowplug light has come on a few times recently (with no loss of power or anything), it just flashes until the car is restarted again. I've noticed this more in the recent wet weather alongside with the boot release which keeps unlocking whilst driving and/or when turning the car over.

Has anyone else had these issues? The car drives fine, the clutch and gearbox feel good. It's a little concerning reading threads relating to quite expensive issues.

Many thanks!

[jeebowhite]

I think it will be the Idle Control Valve, but cant remember if your MK engine has one of these or works on a MAF or MAP sensor.

Can you post a picture of the engine bay?

[mch1991]

I think it will be the Idle Control Valve, but cant remember if your MK engine has one of these or works on a MAF or MAP sensor.

Can you post a picture of the engine bay?

Thanks for your reply! I will post a picture for you shortly.

[mch1991]

Hello,

Sorry for the delay, haven't been able to get on the computer.

Here are some photos I took of the engine.

The car has been behaving the last 2 days actually, no Glow Plug light, or stalling, it only seems to happen when the weather is very wet (as it has been the last few days).

Many Thanks!

[jeebowhite]

Top right of the first pictures, you have the white container with a lid, then just under that appears to be the black air filter and the hose. You will see that there is an electrical connector there.

You will probably need to remove this and spray electrical contact cleaner into the MAF (out of the car) just to clean it up.

It sounds like the engine is getting mixed readings on air, and this is a good cheap place to start!

[sybell86]

hi there i have a 2002 mondeo 2.0 tdci when i am driving my glow plug light some time comes on then my car cuts out and i have to restart it or if doing 50 rebump it can anyone help please many thanks

[jeebowhite]

Hi Simon,

Rather than crossing threads here, feel free to start your own topic in the mondeo section.

[mch1991]

Hello,

Just thought i'd report back. So, the last two days I've had time off and decided to give the EGR and intake manifold a good clean (i couldn't believe the amount of gunk in them), i also gave the mass air flow sensor a clean.

At first the car felt rough, can only imagine it's not had a nice unrestricted air flow for a long time, that with the battery being unplugged then reconected seems to have refreshed the ECU. After spewing out black rubbish from the exhaust, the car is running absolutely spotless. It feels so smooth, the power seems more balanced and the RPMs aren't hunting for idle.

This car feels like it's got a new engine now. very happy! got a new EGR valve blanker coming, Shell fit that and see how it feels.

I strongly recommend people to clean these components, it's easier then i thought it would be. Must have emptied a good kilo of carbon deposits that had strangled almost all of the airflow.

Thanks for the advice! One very happy Mondeo owner.