danlew08

Hi guys can someone help me???????
My mondeo zetec s 130 went into limp mode about a month ago and was diagnosed as a faulty injector number 2, so number 2 and number 4 injector was changed from a salvaged engine, toke it back to local garage and they reconfigured the injectors and still the problem persisted with alot of smoke on cold start up, but smoke goes wene warm, engine runs rough as a old boot, so we told that the duel mass flywheel had gone, so again both flywheel and clutch was changed and still the problem is there.
Please can someone help because i need my car to use for work and i cant work without it
Cheers dan

whitenoise

could be anything on them. fuel pump, fuel solenoid thingy, duff injectors etc

DanW@FastFord

iTrader: (1)

Is it still flagging up fault codes?

A DMF would not cause smoke - I'd put money on it being the injectors. When one goes, the rest are invariably not far behind. It's a lottery fitting second hand ones. A dodgey DMF does not make the engine sound like an old tractor - that will be injectors. A knackered DMF sounds like a rattling bag of spanners.

If I was you I'd get the injectors tested by a proper Delphi specialist - NOT a Ford dealer, and not a non-Delphi specialist, as they cannot test them properly, despite what they may tell you.

A 'local garage' cannot recondition them, and many people claim to offer recon services, but can't do it properly.

At very least do a leak off test and see what the results are. It may not be conclusive, but it could well show an issue.

Also TDCI injectors are notoriously tricky to recode properly, even with the correct Delphi gear - so either the injectors may be duff, or not recoded properly, so they're still running with the previous 'incorrect' settings.

Whatever the outcome there will be no cheap fix - so you may want to consider whether it's worth cutting your losses. You can recoup some costs be breaking the car, as Zetec S bumpers go for good money, as do the wheels.

danlew08

Yeah its sti flagging up fault code

danlew08

On the same injector as before but the 1s we got came from working engine

DanW@FastFord

iTrader: (1)

Then they can't have coded it in properly. The system will not accept a new injector code when there it a fault code.

I 100% guarantee they're not coded in correctly. There aren't many recoding devices that can do it when there's a fault code. If it's not a Diesel specialist they may not have the correct kit. They may well have a coding device, but not one that can clear this particular code AND recode it.

It's tricky even with the proper Delphi Diamand unit! I speak from personal experience of this.

danlew08

Ok thanks for help found a garage with delphi kit so guna try them if it dosent work then i mite burn it
Cheers again

djcossie

short con rod

stevenr

I'm having bother with mine just now too and it's starting to sound like injectors reading this thread.

There are no split intercooler hoses and i've had the EGR and inlet off and cleaned them both out.

Lots of blueish smoke on start when cold but seems to clear when it's warm,won't rev over 3k and absolutely no power at all,turbo doesn't seem to be kicking in.

When it happened first it made a whooshing noise like a hose bursting but i've checked them all again and again and can't see anything wrong.

Gallon of petrol and a match making their way towards my car soon!

danlew08

Thats exactly the same as mine, is it gone into limp mode?

stevenr

Not really sure to be honest,do the dash lights come on when it's in limp mode?

Not had it on a computer yet to check codes ,that's tomorrow but i'll update when i know more.

danlew08

Its the orange coil light on the left of the dash

stevenr

Yes thought so,it's not on in my car though which is the strange thing.I'll wait and see what the computer says later before i do anything else.

DanW@FastFord

iTrader: (1)

The EML doesn't always come on when there are issues.

Is there any oily mess on the outside of the hose? Sometimes it's hard to spot the split. A whoosing noise would definitely be a boost leak.

stevenr

Yes there's the oily mess on one of them,bottom right if you're looking at the engine.

I've had it of though and really can't see anything.The whooshing noise only happened the once and that was it,no turbo afterwards.

It certainly sounded to me like a hose bursting too.

DanW@FastFord

iTrader: (1)

Is there any play in the turbo shaft?

Is there no boost at all, or just at the very top end of the rev range? If so (and presuming yours is a Euro3), it could be either the vac hose to the turbo that's split, or even the diaphragm in the actuator itself. If it's a Euro 4 then a fault code check will reveal if it's the turbo that's bust.

stevenr

Couldn't feel any play in the shaft,checked that first just incase.Should you be able to turn the shaft ?

I got someone to rev it while i listened for leaks today and noticed the pipe from the EGR to the intercooler was being sucked flat,could it be a blocked intercooler i wonder?

It's a Euro 3

DanW@FastFord

iTrader: (1)

Yes, you should be able to spin the shaft freely. If not your turbos knackered - and it would also explain the pipe being under vacuum, when it should be the opposite.

stevenr

Aye it's fucked.Got one coming though so should be back in action soon.

Sorry for the thread hi jack.