Hello you lovely people! please stop me burning my mondeo!!

this is quite long winded but here goes

i bought my Mondeo (2004 53 plate tdci ghia) in may! very nice car but on cold start it would start on the button but wouldn't rev up for 5-10 seconds then it would clear and be ok although a little clacky for want of a better word!! i took it to work and i thought id look at the egr valve, on removing it i found that it had been blanked off and it was very clogged up i removed the blanking plate and cleaned the egr valve and low and behold it run like a dream and the clackiness went, great!!! in the morning the starting issue was still there so i thought id put my fault code reader on it and found it required a manufacture update! i have a friend that can do this so asked him, he did it and the clackiness returned but the starting issue was sorted but i could feel it popping when cruising he told me that 2 & 3 injectors were playing up and to keep an eye on it. well about a month after (july) i booted it off a slip rd and the glow plug light came on and i lost power, i had my injectors tested and was told 3 were bad so i changed 3 of them and kept my good 1 re coded them with the snap on computer! the glow plug light stayed out and the car stopped losing power BUT the clackiness was as bad as ever and the starting issue returned ran it for approx 4 week and as i booted it to join a main rd the glow plug like came on and i lost power so again i take to a mate (a very good ford technician) he did some tests thought it may be an injector problem and told me to get them tested again! he also told me that the variable vain was stuck but to get the injectors tested first so thats what i did, found out that the one injector that wasnt changed had failed! so i changed it so i now have 4 new injectors re coded them glow plug light went out and it was ok (still has the clackiness and the starting issue) until the next day booted it onto a main rd glow plug light came on and lost power! got it to work put the code reader on it came up with a 132a code so i bought a new turbo and actuator fitted them 3 days ago and the fault codes are all gone and it drives well BUT now in the morning it plooms grey/white smoke wont rev up and cuts out once its warm its fine although very clacky!!! any ideas?? over to you lovely ppl!! sorry its a bit long winded but i thought id give you the full picture

every part ive fitted has been new and not second hand

come on guys dont let my car beat you!!! lol

Worn valve stem guides, or worn valve seals.

Leaking injectors or overfuelling.

Basically either your injectors are incorrectly coded or the head is shot.

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Another area to check is the main pipe from the intercooler to the turbo.

A split in the rubber would account for the loss of power on booting it as the turbo spools up and can't balance the intermittent pressire.

How well did you clean the EGR?

If it's still gummed up the valve may be sticking still.

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Cheers Stoney I'm thinking the injectors need coding correctly! I don't think it's the head has it has been ok then plays up I've tried a new egr and it made no difference but the inlet mani was well coked up? Every time I do something it gives me another problem I'm thinking of checking all the turbo pipes and getting the injectors coded by ids ??

Definitely has the symptoms of overfuelling so checking the injectors is a good point to work from.

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Yea it is over fuelling you can smell it too! Pump regulator? Not heard anything about them playing up though? What could cause it to over fuel when cold and is coding them important ? Cause some people say no?

Definitely get the coding done and work from there.

Also worth checking the injector loom.

Injector loom ? Would that be more inconsistent ?

do you know what order the injectors were coded?,as they should be coded in firing order and not physical order, its a mistake some people make.

That's what been on my mind! It's going into fords next week to have all the re coding done and updates! I've done £900 in 4 weeks so I've gone past the point of no return really