Mondeo Les

Hi again,

I have previously posted on this subject but haven't yet sorted the problem (been away a lot) and thought a better explanation would help.

Basically, the car puts out loads of black smoke when driven in a particular fashion. If I drive it with a feather touch on the pedal and drive oh so slowly off from a standstill then the smoke is acceptable - sort of. If I boot it it's ok for a few secs and then woosh, smoke! lots of. I have learned that a long slow down for a roundabout from moderate speed with the throttle closed seems to store up trouble. As soon as I put my foot down, even just a bit, yes, you got it - smoke. I now drive differently and out the clutch down when slowing rather than allowing engine braking.

I say this as I'm hoping it will help with a diagnosis. The car had a new turbo a few months ago and a while after that a new flexy boost pipe to the intercooler. (That was the cause of an earlier smoke problem and associated performance issue. The pipe was split).

Currently, the smoke is the main issue and performance is still pretty good. If I ignore the smoke and on a clear road boot it then it picks up and goes like it always did. I do however think it's a bit sluggish at very slow speeds but given that I spend most of my time looking in my mirror for smoke it's hard to tell!

So, I have read lots about dirty EGR valves and faulty mass air flow sensors and I'm hoping it's one of these. But which first? Can I check something before doing any real dissassembly?

Any thoughts much appreciated.

The Youth.

iTrader: (1)

clean the egr first, easy enough to do

steve

RichieST

iTrader: (2)

Have you checked for any more split / loose pipework? EGR valves are very common on these, they tend to gum up so will need cleaning. I think you can also remove them with a blanking plate, should be able to get one on ebay. I'm sure someone a bit more knowledgeable will be along soon!

Mondeo Les

Had it revving over a pit and gone over all of the hoses. They stress up when the turbo is running due to internal pressure but no leaks apparent.

Mondeo Les

just ordered a a gasket set (?) from main dealer as no one else does it local. The set is apparently just a single gasket. I was expecting 2. Does a single gasket sound right?

Is it easy to get to? The rear bolt looks tricky.

The valve is on the left of the engine (viewed from the front) and is the type with just a vacuum connection.

Anything else worth noting before I get my tools out?

RichieST

iTrader: (2)

Get some carb cleaner from halfords etc to give it a good blast through, you may even want to let it soak in the stuff if it is very clogged. Wear some eye protection though as it comes out the can in a hard fast blast and talking from experience, it does bloody sting!

Mondeo Les

It's been a while but I thought an update may be helpful to someone.

At the end of the day I bought one of those easy fit aluminium blanking plates of Ebay, Ł3.50 inc posteage. My EGR valve was one of the vacuum pipe only (non-electronic) types. The plate was dead easy to fit and took only ten minutes. Just slacken the bolts to make a 1mm gap and slide the slotted plate in position. Retighten bolts.

The effect was not immediate. I still had some smoke but it was much improved. I then had to make a 180 mile round trip to Gatwick and much of that was fast motorway. I guess it gave an opportunity for clearing out all the accumulated crap 'cos while it did smoke embarrisingly when booting it, it has now settled down and after another couple of weeks I'd say it was back to normal. Performance unaffected by the plate and economy is still outstanding. Even driving quite hard to the airport I got over 50mpg,

Sorted!

Mr S1

iTrader: (2)

Got a link for the plate mate ?

Mondeo Les

For EGR in front of engine (like mine):

http://cgi.ebay.co.uk/FORD-MONDEO-MK3-2-0-2-2-TDCI-EGR-BLANKING-PLATE-/130536684780?pt=UK_CarsParts_Vehicles_CarParts_SM& hash=item1e6497bcec

Behind engine:

http://cgi.ebay.co.uk/MONDEO-MK3-2-0-TDCI-EGR-BLANKING-PLATE-REAR-MOUNTED-/130543384792?pt=UK_CarsParts_Vehicles_CarParts_SM& hash=item1e64fdf8d8

defender71-12

Hi mate, after reading your bit about smoke problem i'd check EGR valve. Mine was exactly the same changed turbo no better was considering changing injectors but gave EGR a good clean first,only took an hour. cloaking device gone....

gingerxr2

done this on my dads and it sorted smoke out a lot,might have to get him a plate aswell tbh

Bad Boy Al

My 55 mondeo chucks loads out if I boot it an sometimes goes into limp mode. I drove it hard in limp mode but no smoke. Think turbos had it or any ideas. Have cleaned the egr valve which was bad but still does it. Anyone help.

Al