Mondeo TDCI 2002 cut out problem?
05-04-2011, 04:37 PM
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Mondeo TDCI 2002 cut out problem?
Hi all,
Firstly I must appologise for my first post being a question to a problem I have,not a good way to start I guess but I am pretty stuck at the mo so any help would and will be very much appreciated.
I have just brought a mondeo tdci ghia x estate 2002,nice car but I have a cutting out problem,I have searched all the posts on most of the sites but cannot find anything similar to my problem.....?I have found many posts with the cutting out problem but not the same as the one I have.
1. On starting the car from cold it starts first time with no untoward noise or smoke and drives fine until you hit 3,000 revs at which point the car shuts down and you have to turn the key off and then it will restart immediately.
2. If you let the car warm up to normal operating temperature then it will drive and rev all the way up to 4,000 revs with no problems at all....if you rev above 4,000 revs then it will cut out again.
3. The car pulls like a train,does not burn oil and the turbo is fine,there is no judder on the engine etc to suggest a pump or injector problem and the car only cuts out at the revs I have pointed out...otherwise it will drive all day long!
I have just changed the fuel filter and found loads of emulsion in it along with the normal crap you get in there,there were no metal filings etc but to be honest I have never seen so much crap come out of a filter.
Having done that I restarted and had a drive around and didnt really see any difference so parked it up and opened the bonnet for another look.......
On looking around under there I noticed diesel seeping/bubbling from the front of the engine......There is a rail that sits just under the head with four adjustable nuts connected to it.....one of these adjustable screw/nuts that goes into the engine was bubbling diesel out of it where it goes into the engine.
It would suggest to me that when the engine is cold this leak would be much worse than when its hot hence maybe the car cuts out at much higher revs than when cold???????????
Can anyone tell me what these adjustable nuts/screws are and what they do? can anyone otherwise shed any light on the problem?
Many thanks to all for taking the time to read and any replies !
Regards all,
Paul.
Firstly I must appologise for my first post being a question to a problem I have,not a good way to start I guess but I am pretty stuck at the mo so any help would and will be very much appreciated.
I have just brought a mondeo tdci ghia x estate 2002,nice car but I have a cutting out problem,I have searched all the posts on most of the sites but cannot find anything similar to my problem.....?I have found many posts with the cutting out problem but not the same as the one I have.
1. On starting the car from cold it starts first time with no untoward noise or smoke and drives fine until you hit 3,000 revs at which point the car shuts down and you have to turn the key off and then it will restart immediately.
2. If you let the car warm up to normal operating temperature then it will drive and rev all the way up to 4,000 revs with no problems at all....if you rev above 4,000 revs then it will cut out again.
3. The car pulls like a train,does not burn oil and the turbo is fine,there is no judder on the engine etc to suggest a pump or injector problem and the car only cuts out at the revs I have pointed out...otherwise it will drive all day long!
I have just changed the fuel filter and found loads of emulsion in it along with the normal crap you get in there,there were no metal filings etc but to be honest I have never seen so much crap come out of a filter.
Having done that I restarted and had a drive around and didnt really see any difference so parked it up and opened the bonnet for another look.......
On looking around under there I noticed diesel seeping/bubbling from the front of the engine......There is a rail that sits just under the head with four adjustable nuts connected to it.....one of these adjustable screw/nuts that goes into the engine was bubbling diesel out of it where it goes into the engine.
It would suggest to me that when the engine is cold this leak would be much worse than when its hot hence maybe the car cuts out at much higher revs than when cold???????????
Can anyone tell me what these adjustable nuts/screws are and what they do? can anyone otherwise shed any light on the problem?
Many thanks to all for taking the time to read and any replies !
Regards all,
Paul.
09-01-2012, 10:23 PM
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reply to your question for cutting out
Hello, well i have a mondeo tdci 2002 and i have just started having a problem with mine cutting out under load, more so after accelerating while in cruise control.
I have not done any diag yet but will be tomorrow, first thing i will check is the injector leak off, under differing conditions this can cause simmilar symptoms.
drives fine but when loaded up looses power, but not all the time, then i will check prv, pressure relief valve on the end of the rail, there should be no discharge of fuel, after that i will look at sensors, these can be checked with a multimeter set to measure ohms, a typical inductive sensor should read somewhere between 1150 to 1850 ohms.
the fuel control solenoid should measure a lot less, usually around 20 to 30 ohms at twenty degrees coolant temp.
these can be difficult to check without a scope as you need to measure the square wave form, if it is reading a wide pulse width, there could be a fault mechanically, it goes to full fuel volume and you will see fuel pressure irregularities, the ecu will pick this up and activate the fault light.
I have personally serviced this vehicle throughout and found no problems with swarf or diesel bug,( jelly) in the filter and i have removed the egr, cleaned and checked it and all piping with a mityvac vac pump.
If i can sort this i will post what i find.
I have not done any diag yet but will be tomorrow, first thing i will check is the injector leak off, under differing conditions this can cause simmilar symptoms.
drives fine but when loaded up looses power, but not all the time, then i will check prv, pressure relief valve on the end of the rail, there should be no discharge of fuel, after that i will look at sensors, these can be checked with a multimeter set to measure ohms, a typical inductive sensor should read somewhere between 1150 to 1850 ohms.
the fuel control solenoid should measure a lot less, usually around 20 to 30 ohms at twenty degrees coolant temp.
these can be difficult to check without a scope as you need to measure the square wave form, if it is reading a wide pulse width, there could be a fault mechanically, it goes to full fuel volume and you will see fuel pressure irregularities, the ecu will pick this up and activate the fault light.
I have personally serviced this vehicle throughout and found no problems with swarf or diesel bug,( jelly) in the filter and i have removed the egr, cleaned and checked it and all piping with a mityvac vac pump.
If i can sort this i will post what i find.
10-01-2012, 09:42 PM
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Well, some degree of success, first thing I did was to test my injectors by carrying out a leak off test and hey presto, number one and two are faulty.
I don't know what the measurements should be but I got, one, ninety five millilitres, two went out the bottle, three twelve and four, twenty five, I did this test over one minute on idle with the engine temp up to running temp.
I would expect to see a differential of around ten percent per injector.
the kit I used cost me 175 pounds for a master kit and looking at some of the problems people are having with agents it was money well spent.
I will fit new units and let you know the results.
If anyone can tell me what the measurements should be it will be appreciated.
I don't know what the measurements should be but I got, one, ninety five millilitres, two went out the bottle, three twelve and four, twenty five, I did this test over one minute on idle with the engine temp up to running temp.
I would expect to see a differential of around ten percent per injector.
the kit I used cost me 175 pounds for a master kit and looking at some of the problems people are having with agents it was money well spent.
I will fit new units and let you know the results.
If anyone can tell me what the measurements should be it will be appreciated.
11-01-2012, 12:14 AM
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I worked for a diesel specialist for 5 yrs & lost count how many mondies,trannies & jags we had in with simlar faults
the only downside is it could be a few things
sounds like fuel pressure is getting too high tho & going into limp home mode
could be fuel pressure reg
injectors or poss pump
to do a crude leak off check on injectors
you take the leak off pipe off all 4 injectors (hold on by horse shoe type clips)
After the last 1 (cyl 4)
Crimp it but not too tight with mole grips etc
take the multi plugs off injectors
blow the diesel out each injector at top where leak off pipe was
then put ignition on for 5 seconds check for fuel at injector top ( leak off return )
Shouldnt be any or very little.
Then crank engine for 3-5 secs check again if 1 or 2 have lots & others have little diesel showing
the ones with lots are bad injectors
as for the gunk ya found in the filter
it sugests its been ran on dodgy fuel to me as water in the fuel causes the jelly stuff you found
id be tempted to keep checking filter & if it gunks up.again id drop the tank & steam clean it out as it will be sludged up
( common if its been run on red or home brew bio)
As your car keeps cutting out it should flag up fault codes
it might be worth taking it to a diagnostic centre
they will put the scan tool on it & drive it why conected to read the fuel pressure under load
check each injector
rail pressure etc
should be able.to give you answers from that if there any.good
if your local to nottingham
take it to gee diesel services
they will bottom the prob in no time
the only downside is it could be a few things
sounds like fuel pressure is getting too high tho & going into limp home mode
could be fuel pressure reg
injectors or poss pump
to do a crude leak off check on injectors
you take the leak off pipe off all 4 injectors (hold on by horse shoe type clips)
After the last 1 (cyl 4)
Crimp it but not too tight with mole grips etc
take the multi plugs off injectors
blow the diesel out each injector at top where leak off pipe was
then put ignition on for 5 seconds check for fuel at injector top ( leak off return )
Shouldnt be any or very little.
Then crank engine for 3-5 secs check again if 1 or 2 have lots & others have little diesel showing
the ones with lots are bad injectors
as for the gunk ya found in the filter
it sugests its been ran on dodgy fuel to me as water in the fuel causes the jelly stuff you found
id be tempted to keep checking filter & if it gunks up.again id drop the tank & steam clean it out as it will be sludged up
( common if its been run on red or home brew bio)
As your car keeps cutting out it should flag up fault codes
it might be worth taking it to a diagnostic centre
they will put the scan tool on it & drive it why conected to read the fuel pressure under load
check each injector
rail pressure etc
should be able.to give you answers from that if there any.good
if your local to nottingham
take it to gee diesel services
they will bottom the prob in no time
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