Mondeo Black Smoke No Power And More

[Atomix]

Hi, first post here and i have a few issues with my mondeo which i could really use some help with. Its a 2006 mondeo lx 2.0tdci 130ps euro 4, 111k, new.dmf and clutch but recently its developed a few issues... to start with it only starts with easy start, idles rough with revs going up and down a little and shakes slightly which can be felt from inside the car, it also feels like its about to cut out which sometimes it does, i have lots of black smoke all the time even at idle, also when i pull away theres a loud tapping which turns into a fast vibrating sound as i drive over 2500rpm. It doesnt make the noise when i rev in neutral, only under load. The garage diagnosed a turbo code and im in the process of removing turbo for a clean in the vanes etc but its very annoying removing it. I bought a code reader of eBay and got codes p0100 and p0251, ive cleaned the mass air flow sensor and reset codes but no difference and havnt had any more codes come up. Im suspecting that the turbo isnt going to be the problem and i would have removed it for nothing! The actuator arm was stuck so i freed it up but no difference to rough running, noise and black smoke. Could the vanes still be sticking even though the actuator arm is free? Any advice much appreciated, thanks, chris

[wase16ll]

p0251 is a fuel metering code.

if you can, do a leak off test on the injectors to start with

can also be down to something as simple as a fuel filter, so worth changing just to eliminate it or the injectors need recoding

beyond that, code could flag up due to fuel pressure problem such as the rail pressure sensort or pressure solenoid (both are known for wiring problems so check the connections) or the dreaded pump.

ford diesels are notorious for diagnosing, often the fault can be hard to relate to the codes that flag....bearing that in mind, do the simple stuff such as checking the air filter, turbo hoses for splits, cylinder head temp sensor, egr for blockages

[Atomix]

Thanks, after ive done turbo tomorro i will do a leakoff from injectors, fuel filter was changed 2 months ago by a garage as part of a full service although it could be a crap one so might replace again with ford one, ive removed and cleaned the egr which wasnt that bad but its hard to push the valve...must be a hell of a spring inside that! Ive checked all pipes for splits and there isnt any so ill report back after turbo cleaned and refitted and a leak off. Is it possible the turbo vanes are stuck even though the actuator arm moves freely after i loosened it? Im thinking they could be stuck resulting in air going to waste and injectors not realising and still putting thru same amount of fuel which isnt burning properly? The noise worries me the most at the moment its like a tap tap tap with engine speed but only under load, then at half throttle or less it starts sounding like the chain is slipping or something and almost no power. Aaarrghh lol

[wase16ll]

could be right with the turbo, not something i have seen on a ford though

egr spring is strong so no problem there...

with regards to the noise...have you pinned it down to an engine mechanical knock or could it be an external ancillary component?

common problem giving a tap/knock are the dmf or the crank pulley so worth checking

by the way, would agree with getting a quality filter, known issues with some aftermaket ones

[Atomix]

Think i could have found the source of the tapping and vibrating (hopefully). Take a look at the video i just made and could somebody please tell me why that circular disc is free to rattle about behind the turbine wheel????? Many thanks, chris. Also my vanes are sticking at high and low positions so will blast everything out and clean them right up! I look foward to replies as i dont know whether to undo the shaft and mess around with the disc and not have the turbo balanced when i do the nut back up on the shaft, help meeeeeeee lol

[Atomix]

Heres the video...

capturedvideo.MOV

[wase16ll]

that doesnt look good....havent stripped enough ford turbos to be sure, but can only think that disc has broken away from the wheel, which case dont think it can be repaired