Mondeo TDCi starting and preformance problems

[SteveN57]

I have a 2004 Mondeo TDCi 130 (230,000 miles - yes you read correctly). 12 months ago had a new set of injectors fitted and car ran fine until about a month ago.
On starting from cold, engine does one of two things. 1 - fires up but only idles at about 600rpm and will not rev. after anything from 10 seconds to 1 minute idle speed increases to about 750-800 rpm and engine behaves normally. 2 - fires up but revs are "all over the place" - anything between 500 and 1500 - and lots of "blue smoke".
Second problem occurs when I "wind it up" above about 3500 rpm, at which point car goes into "safe" mode and glow plug warning light flashes. This element of problem disappears if I stop the car, turn off and re-start.
I have had injectors checked by a specialist who advised all OK and readings within acceptable parameters. Local Ford dealer (who I must admit I do not trust one iota) says I need a new turbo-charger!?
My local garage checked out and advises two codes logged - P1608 (injection pump internal fault) and P2263 (unknown fault - turbo boost pressure performance problem). I am told one fault could trigger the other and replacement of injection pump is going to set me back something in excess of £1000.
Does any body have any suggestions - apart from drive the car into the nearest deep water and forget about it?

 

[Burnerman]

Indeed, I also would suspect a turbo problem, but a diesel specialist would be able to check the boost pressure and wastegate performance for you.
230,000 miles? Ford should buy it back and give you a spankers one!
John

 

[SteveN57]

Thanks for your thoughts. What I can't figure though, is how a faulty turbo would cause starting problems. I did read on another forum that problem could be as simple as a faulty camshaft sensor (a quick and inexpensive repair). For the sake of a few quid think I might try this and see if it at least solves the starting problem. Can't see it doing any harm.

 

[Burnerman]

I agree about that side of your diagnosis....a compression test wouldn't do any harm, as indeed would a glow plug check (if it has them).
Sorry i can't help with fault codes though - although I am aware of software upgrades for these. Dont like the sound of injector pump faults!
John

 

[Mickymoody]

Thanks for your thoughts. What I can't figure though, is how a faulty turbo would cause starting problems. I did read on another forum that problem could be as simple as a faulty camshaft sensor (a quick and inexpensive repair). For the sake of a few quid think I might try this and see if it at least solves the starting problem. Can't see it doing any harm.

Turbo leaking oil, thus causing the oil leak?

Have you pulled the plugs to see how the engine is running?

New injectors have caused stress on other items?

What's a 2004 Mondeo with 230k miles on the clock worth? £10.50? Why attempt to repair it when there are millions out there, with less miles, in better condition? That WORK.

Bin it.

 

[SteveN57]

Replaced camshaft sensor but made no difference. Ho hum!

 

[Belle427]

you could guess for weeks at a fault like this and throw hundreds at it, a good diesel specialist should be able to diagnose quickly. With the right kit they should be able to test the fuel pump etc and pull any fault codes from it.

 

[Mickymoody]

Re-reading the post, it does sound like a fuel pump failing, my non TDCi Ford blew out loads of blue smoke, before the pump failed completely.

Can you manually prime the pump, and get better results?

Even after a new pump was fitted, I still had results, that you describe, so airlocks in the fuel system, faulty pump?

AH! PING! You had the injectors off for testing - therefore a airlock. 2+2 suddenly! Bleed the system.