I have a 2004 Mondeo TDCi 130 (230,000 miles - yes you read correctly). 12 months ago had a new set of injectors fitted and car ran fine until about a month ago. I now have 2 problems (related?)

First problem - on starting from cold, engine does one of two things. 1 - fires up but only idles at about 600rpm and will not rev. after anything from 10 seconds to 1 minute idle speed increases to about 750-800 rpm and engine behaves normally. 2 - fires up but revs are "all over the place" - anything between 500 and 1500 - and lots of "blue smoke".

Second problem occurs when I "wind it up" above about 3500 rpm, at which point car goes into "safe" mode and glow plug warning light flashes. This element of problem disappears if I stop the car, turn off and re-start.

I have had injectors checked by a specialist who advised all OK and readings within acceptable parameters. Local Ford dealer (who I must admit I do not trust one iota) says I need a new turbo-charger!?
My local garage checked out and advises two codes logged - P1608 (injection pump internal fault) and P2263 (unknown fault - turbo boost pressure performance problem). I am told one fault could trigger the other and replacement of injection pump is going to set me back something in excess of £1000.
Does any body have any suggestions - apart from parking the car in the nearest deep water and forget about it?

 

http://www.fordwiki.co.uk/index.php/Category:Mondeo_Mk3

might find an answer on there

 

injection pumps are a common problem on the tdci. if you shop around you can pick a recon pump up for around £200, they are reasonably easy to fit but not a DIY job, so you could probably get it fitted for £200 - £300!! try the back pages of autotrader theres usually a few ads in there for recon pumps!

 

sounds like 2 problems to me.

1. fuel pump is fucked, common to go along with the injectors as modern tdci engines run insanely high fuel pressure. this higher pressure means more fuel system component wear, more unreliability and higher cost of repairs!
2. intermittent boost problem either caused by a boost leak or a problem with the turbo.

if the engine is still standard i expect the intake is filled up with crap from the egr system which has reduced its internal diameter to fuck all (5p coin or less) and probably also clogged the variable vains in the turbo up to the point where the turbo needs to come off and be reconditioned.

all of these will cause running problems and they are common problems on ALL common rail diesel engines, not just fords, hence why i dont like modern diesels!!

your best bet is to take the car to a modern diesel specialist, no normal garage is going to be able to sort these problems and i doubt very much that you will find a main dealer in the whole country able to either. problems like this get discussed on here all the time so just do a search for diesel specialists and i'm sure you'll find something.

good luck but i can see this being costly, very costly, and with 230,000 miles on the clock your prob best getting rid. go and trade it in and give the dealer the problems, though they'll just send it to auction.

 

Did you ever solve the problem as mine does the same, idles badly on startup then runs perfectly after 5 mins?