Ford Mondeo Graphite TDCI 2003 several issues

tzb27

Car was idle for three weeks when I went away for my holidays and at first start the dashboard resets itself - the recent driven miles reset to zero, all the dials go up to the top and then come back to zero, as does the fuel gauge which then reverts to what fuel is in there. this happens while holding the key over and then the car started. This happen a couple of time on four weeks span. In fifth I left the car parked for 12 hrs and then in night it wouldn't start. Engine was turning over but not firing. In the end we managed to jump start the car and everything seems fine for five days. On weekend car wasn't firing again and i ran the battery down. Called the recovery out and it was another jump start. Recovery guy told me to change my battery which I did and put in Bosch Battery (S4 Battery 100 (72Ah) 4 year warranty)

After changing the battery car was working fine and no issues with starting the engine. Someone suggested me to use Redex Diesel treat. I fueled the car to full tank and used redex as per instructions. There weren't seem to be any issues on the day but following day car just died while driving on A40. I got the car some how to hard shoulder and tried to start the car couple of times and it worked. Then car drove for two days without any issues and died again in the middle of the road. I managed to start the car this time as well and blamed Redex for such behavior. Following weekend I did a short trip to the local shops and parked the car outside the house. This was it then car didn't start, it was turning over but not firing. I ran the battery down completely and did try to push start but it didn't work. I got the recovery out they tried jump start and pull start but no luck.

After a recommendation I got my car recovered to garage in Alperton. He carried out following work on it:

- bleed the system
- changed Injector 1 and 3
- oil/filter change

Car was fine for two days but refuse to fire on third day but I managed to start after couple of tries. I took the car back to garage again and following works were carried out:

- crankshaft
- camshaft sensor
- power steering pump (It broke down while doing push/pull start)
- EGR valve


Since these sensors are changed following faults can be noticed:

- Glow plug light came on following day (I went back to the garage straight away and mechanic is just playing games now. excusing himself to take the car because he is busy. Also saying I bought the car with faults maybe turbo and fuel pump is gone. My question is why didn't he notice this before changing filters.)

- While trying to start the cold engine a lot of white smoke comes out and it's don't fire for couple of tries. This white smoke disappears as soon as car starts.
- After mange to start the car idling jumps and car is lumpy for a while and it stays below 1000 RPM. Seems like car have lost the power (Good example: http://www.youtube.com/watch?v=-X4iDMVx_Sk)
- Sometimes i can smell burn oil inside the car
- There is burn oil smell if stand near the exhaust but no oil on the floor where car is parked.
- While driving steering seems to pulling on each side
- Rear inside break light is gone. (I think it's not the bulb but some switch.)
- Side light on speedometer are not lighting up.

All along it seems like electric faults which are not dealt properly.

I will much appreciate if you can contribute something to these problems. I am looking for a good mechanic who understand these issues rather than asking me to change this and that.

forgotmyname

The dial sweep is a sign of a flat or very weak battery.

All the brake lights work off one switch. So if only one bulb or set of lights are broken its not the switch. Fuse, Bulbs or wiring issue.

Pulling to one side, Checked the tyre pressures?

Dash lights, Bulbs or switch.

You need to read the fault codes. Early 2003 cars are not OBD compliant so cheap handheld readers wont work.

If you have a laptop then you can buy an F-Super off ebay for less than £15. That will read the codes on early and later cars.

Lost power could be a split turbo pipe or its in limp mode (flashing glowplug light)

tzb27

It's a brand new Bosch battery and thanks for your advice.

forgotmyname wrote: »

The dial sweep is a sign of a flat or very weak battery.

All the brake lights work off one switch. So if only one bulb or set of lights are broken its not the switch. Fuse, Bulbs or wiring issue.

Pulling to one side, Checked the tyre pressures?

Dash lights, Bulbs or switch.

You need to read the fault codes. Early 2003 cars are not OBD compliant so cheap handheld readers wont work.

If you have a laptop then you can buy an F-Super off ebay for less than £15. That will read the codes on early and later cars.

Lost power could be a split turbo pipe or its in limp mode (flashing glowplug light)

forgotmyname

Brand new or not. It wont stay brand new for long if the charging system is not upto the job.

The dial sweep is an indicator of voltage issues as i mentioned a flat or weak battery usually.

Test the voltages 1st thing in the morning before you attempt to start the car. Then test it again when the engine is running and under electrical load.
Heated (rear) screen, headlights, heater blower on full.

Not the heated front screen which draws a LOT of power. Does the front screen switch on as soon as you start the car?

tzb27

I am not tech guy at all and don't have the tools for such things but if only can find an honest cheap mechanic that will be dream come true.

Yes front screen switch on as soon as car starts.

forgotmyname wrote: »

Brand new or not. It wont stay brand new for long if the charging system is not upto the job.

The dial sweep is an indicator of voltage issues as i mentioned a flat or weak battery usually.

Test the voltages 1st thing in the morning before you attempt to start the car. Then test it again when the engine is running and under electrical load.
Heated (rear) screen, headlights, heater blower on full.

Not the heated front screen which draws a LOT of power. Does the front screen switch on as soon as you start the car?

Richard53

tzb27 wrote: »

- While trying to start the cold engine a lot of white smoke comes out and it's don't fire for couple of tries. This white smoke disappears as soon as car starts.

...

- While driving steering seems to pulling on each side

Rule of thumb - grey smoke is unburnt diesel fuel, possibly a glow plug fault (engine isn't hot enough to burn clean at start-up), white smoke is water (internal leak, e.g. head gasket).

Mondeos seem to be very sensitive to tyre wear. Mine pulled like mad to the left and I took it to the local Ford dealer, asking if the tracking could be checked. He looked at the tyres (about 3/4 worn) and said 'put some new tyres on it and see if there is still a problem'. I thought I was being fobbed off, but new tyres cured it.

tzb27

Do you think mechanic had to remove head gasket while replacing injectors?

I recently changed right hand side front tyre and left rare tyre. Maybe others need replacing as well. Steering is not a main concern at this point.

Thanks

Richard53 wrote: »

Rule of thumb - grey smoke is unburnt diesel fuel, possibly a glow plug fault (engine isn't hot enough to burn clean at start-up), white smoke is water (internal leak, e.g. head gasket).

Mondeos seem to be very sensitive to tyre wear. Mine pulled like mad to the left and I took it to the local Ford dealer, asking if the tracking could be checked. He looked at the tyres (about 3/4 worn) and said 'put some new tyres on it and see if there is still a problem'. I thought I was being fobbed off, but new tyres cured it.

arcon5

tzb27 wrote: »

Do you think mechanic had to remove head gasket while replacing injectors?

I recently changed right hand side front tyre and left rare tyre. Maybe others need replacing as well. Steering is not a main concern at this point.

Thanks

No, nowhere near. Injectors merely involves unbolting fuel line. Using an injector tool to unscrew then pull out of head.

HG would be a major job, involving removing most of the components surrounding the engine, both auxiliary belts, timing chain etc etc. Replacing HG would typically take a couple of days + time having the head skimmed

forgotmyname

As above removing the injectors is a simple task. Like removing a sparkplug. Except it has a fuel pipe on the top.

The dashboard tells you the voltage. But you need a few other tests also. So you may as well get the mechanic/garage to test the battery/alternator also.

When was the fuel filter changed last? A standard service will usually forget that unless you specifically ask for it to be done.

bigjl

Not knowing if it is a 115 or 130 bhp version.

But I always assumed that injectors needed to be coded on this age Mondeo

I think your garage has either not changed the injectors, did but didn't recode or they have misdiagnosed.

Wasn't aware you needed to bleed a common rail system other than those that have no lift pump in the tank

Been a while since I sold my mk3 130tdci but I never had any issues with airlocks or non starting after a fuel filter change. Different story on the newer Mondeo I suspect as if they are the same as the Focus/V50 which share the engine and have no lift pump or hand primer.

First port of call may be a better garage or diesel specialist.

bigjl

There is a common failure of a boost pipe near the radiator I seem to remember, am sure it went on mine, but think only issue was black smoke and drop in power.

Smoke at startup certainly sounds like Unburnt diesel to me.