Hello. New here today.

I have the dreaded glow plug light on dash problem with my 2003 Mondeo tdci. 120k.

Came on during a trip down to Cornwall. Now its hard to start when left overnight. Car runs fine once engine is warmed up
tho. Turbo kicks in fine.

Checked the glow plugs and none was working so thought that must be the problem. Replaced with four new NKG. Now car starts fine and idles ok, but as soon as you try to rev it, blue smoke from exhaust and hesitates to increase revs (lumpy).

My mate who has a diagnostic says it could be the fuel rail sensor pushing to much fuel into the engine at low revs. Just tried a new one, no difference.

So far I have changed: Air filter, fuel filter, oil and oil filter, cleaned out EGR and inlet manifold.

Could it be one of the injectors? Would that be causing the problem of the smoke?

As the car runs fine and pulls well, once warm I can't see that it is a major mechanical problem.

Any ideas anyone?

Thanks

Checked the glow plugs and none was working so thought that must be the problem. Replaced with four new NKG.

What test did you do to determine that the glow plugs were not working?

My mate who has a diagnostic says it could be the fuel rail sensor pushing to much fuel into the engine at low revs. Just tried a new one, no difference.

Well, I'd say that was one of the unlikelier possibilities. Is it true that your mate did not see any other failure codes, though?

So far I have changed: Air filter, fuel filter, oil and oil filter, cleaned out EGR and inlet manifold...Could it be one of the injectors? Would that be causing the problem of the smoke?

I would think that the most likely thing is a leak in the pipes from the turbo to the inter-cooler or from the inter-cooler back; now, while these might be amongst the cheaper faults to cure, it isn't always apparent where there is a leak, without a really good inspection.

If it was one injector, I think you'd probably see the smoke coming out in pulses, at least at low rpm.

Took old glow plugs out and tested on a spare battery. None got hot. Tested new ones the same way, all glowed bright red.

The diagnostic said fuel pressure was too high so tried new sensor. Next thing is a new fuel pump which is just too expensive. Can't see that its the pump as I drove 260 miles back from Cornwall without any probs.

Just been out for drive in it and after it conked out while belching out blue smoke at junctions, it drove fine after 10 mins. Also, I thought the turbo was working but it's not. Doesnt seem to be running of 3 or less cylinders so all injectors seem to be working.

It it was an intercooler leak I would have thought that the car would not perform whether hot or cold? WIll have a look under the engine tomorrow just to check.

Forgot to mention... also blanked off EGR until I can get this fixed..

I think it has to be a cold temp sensor somewhere.... but where!

Not sure whether to dissconect battery overnight to see if that resets the ECU?