Hi,

mondeo 2.0 tdci 130 2002


i have a flashing coil light, difficaulty starting form cold but fine when warm drives terrible from cold but okish on reduced power when warm and very smoky with un burnt fuel on starting, but not so bad when warm this all started in a instant out of the blue,

had the codes read (cant remember the codes tho) also found out the alternator was charging at 130%-obviously 30% more than it should the fault codes were some thing to do with cylinder 2 and a electrical fault code

the fault code explanations on google recommended i do the following so i did, i changed the fuel filter and had the injectors reconditioned, the injectors are all in bled and running my car is permanently in reduced power mode still though and running smokey-unburnt fuel, fuel economy is un changed its normally a good sound engine.. very economical and pulls like a steam train

just for the record it needs a new crank pulley and auxillary tensioner as it squeaks could this effect the alternator and some how the running of the car

the dmf and clutch are nearly new and sound

on turning off the engine there is a electrical buzzing noise immediately it lasts approx 1-1.5 secs and comes from the rocker cover turbo area=possibly under the turbo and out of sight, this noise has started since the whole fault started...


whats the problem and whats under the rocker cover thats electrical and can buzz..

is there any suggestions on fault

you guys are my only hope before the garage charges me a fortune

i dont think any one can crack this one ive searched every were

the egr is clean and working fine

my turbo is good

i dont know how to test air flow sensor maf sensor but have cleaned it to spotless, with wynns carb cleaner as per ford wiki not sure what a faulty one would do any way althought it looks like there is some sort of resister on the sensor,.... the cleaner is mega cold and i heard a pop like 1 bubble of bubble wrap popping hope the cold was not damaging the resistor on the sensor


when held at 3k revs it revs fine

 

buzzing will be electronic turbo actuator

how did you mark the injectors when they were re-conned?

 

engraved each corresponding to each cylinder and noted the codes they are all back in correct cylinder car runs the same as before injector re con

 

would this electronic actuator cause these problems- especially the smoke and un burnt fuel

what do you make of this

would this make a buzz cause loss of power ( like theses no turbo) and smoke and poor starting

 

Are you sure the 2002 TDCI has an electronic actuator? - i would have thought it had a pnumatic actuator

 

have u done compesoin test yet i would start there

 

hi mate, Firstly I over haul Delphi Common rail injectors for a living, if they have been done correctly you should have brand new codes , but if you haven't they have not been done properly, they have to be ut through a long and thorough test on a specific bench which costs 40k , they need to be recoded using ids software, this will fine tune each injector to get the best out of them i.e fuel economy performace , and sometimes can stop engines running rough and smoke etc, as for the buzzing sound if its coming froim the rocker cover area it will be the valve in the injector that's 2mm in dimension and moves micron in mili seconds its miving that fast it makes a sound like a duck . I would take your injectors out again and send them to Colchester fuel injection ltd where I work cheers

 

and how much is this coding do you need the injectors and the car or just the injectors

 

just the injectors we will run the injectors through a full test to see of any faults, where did you get the over hauled?, I guarantee they have not been properly so really they need doing again, first of when un doing the capnuts you have to out a cut around them to stop dowels in the body turning when un doing otherwise you will put a microscopic bur on the face of the body and it will be scrap, once we have tested or overhauled them they will come in bags with the new codes put on the injectors any garage with a snap on etc diagnostic tool can input the new codes into the ecu

 

mondeo spares stoke on trent re conditioned them, i marked each to go back in the same cylinder and was told they dont need recodeing if they go back in the same cylinder, my pal had the same job done and his was never re coded, how much does this service cost ŁŁŁŁ

the car is going in to my local diesel specialist in the morning

 

used the special purpose made socket to fit and remove the injectors

 

We overhaul them for 142 +vat each, that's rubbish mate they do have to be re coded once they have had a new valve and nozzle the characteristics have been changed hence the code is different , who ever done them are telling bollox, and I meant the capnut on the injector not the tool you take them off

 

Of topic a little bit but I have a one were it whistles if you know what a mean you can here it coming threw the veents

 

Complete bullshit. If they reconditioned them then they would HAVE to give them a new code, and you would have to have them coded to the car. They probably just chucked them in some cleaning fluid.

The act of properly reconditioning injectors involves generating a new code every time - Which is why I'd ALWAYS recommend going to a Delphi specialist.

All your issues sound injector related (but get the aux belt/pulley/tensioner done). Get the injectors either replaced, or reconditioned by someone who knows what they're doing.

Don't worry about the noises once you turn the car off, it's nothing to worry about.

 

Whistling, or whooshing? If it's whooshing then it's a split boost hose.

 

As Danw said send them to a Delphi specialists I.e colchester fuel injection ltd

 

compression it fine

 

theres complete kits on ebay Ł150 ish for all pulleys tensioner and a belt so the whole lot is new i was gonna get this and fit it my self as it seems ok for a diy job,
it seems to make sense to do the whole lot in one as so not to have a old worn part in there playing up the new, the question is are these kits any good , they seem excellent value and proberbly just a afternoons work!!

 

Really needs a leak-off test doing on the injectors , it's the way Ford recommend dealers to test them. - as previous posters mention, a re-con injector if done correctly will need to be re-coded.

I did a write-up on here a while back about the leak-off test, will see if I can find it.

 

so bearing in mind ive hAd injectors re conditioned if the leak of test said they was healthy would the old code be acceptable---and yes i know puka recodeing always has a new code too im just trying to work out could a new code be produce for my injectors if put on a delphi test bench or if my mondeo has FORGOT the old codes as i suspect that was the problem in the first place.

if i can get it out of limp home mode at a reasonable cost ill fit a new injector rail fuel pump as a matter of precaution,----i think this is the expensive important one isnt it