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Mondeo IV 2008 1.8 TDCI FFBA misfire
Posted 04 June 2010 - 11:22 PM
I hope someone may have come across this problem and shed some light on the subject.
Car is a 2008 Mondeo 1.8 TDCI with FFBA Euro 4 engine. Engine has 35K Miles on the clock.
Injectors are Siemens piezo. Car starts easily and idles fine at all temperatures.
A serious misfire starts at 1200 RPM with a lot of smoke (especially under load) up to about 1800 RPM. Once the revs hit about 2500 car runs OK and is off like a rocket.
Car spent months at main dealers who have washed their hands of the car. Car had accident damage at about 12K miles but no engine damage. They claim this voids any warranty which in my mind is BS.
There were no issues from 12K miles to 35K
I have done a lot of Common rails and never been beaten but this one is challenging!!
Dealer has :
Checked Dual Mass Flywheel = no problems
Swapped injectors with another car - no difference
Updated ECU to latest software
Returned car worse than what it was (according to customer).
Found no relevant DTC's at any stage
Blanked off EGR - no difference
Checked current waveform to each injector with PICO Scope at 900,1200,1800 ,2500 for each injector . Each injector seems to have same waveform.2 pilot injections & 1 main up to 1800 RPM ,1 pilot injection & 1 main at 2500. Intake is moderately clean and no sign of excessive fouling of EGR or intake.
MAP.MAF,Boost Press, Rail Press ,air and coolant temp all read normal and as expected
Checked that coding is correct for all injectors.
I am really at my wits end with this one and any help would be really apprerciated
Posted 05 June 2010 - 12:31 AM
Posted 05 June 2010 - 08:28 PM
The only thing I can think is perhaps the inlet air temp sensor is faulty, although it looks like you've checked that.
Is the VNT on the 1.8 vacuum controlled or moved by a stepper motor? I seem to remember it's electrically actuated on the 1.8s. Perhaps the VNT is at fault? But I would have thought you'd get an under/overboost fault code ...
Posted 09 June 2010 - 10:07 PM
Posted 09 June 2010 - 10:09 PM
Air temp sensor reads fine on scanner as does boost pressure which pretty much rules out VNT.
Thanks for your help anyway.
Posted 10 June 2010 - 01:52 PM
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Posted 13 June 2010 - 11:25 PM
Posted 21 October 2010 - 01:49 PM
Posted 21 October 2010 - 08:45 PM
Posted 22 October 2010 - 09:47 AM
I would say it could be a dicky sensor. But which one of the myriad. I'd be afraid to change a crankshaft sensor that I got when it stopped up the last time in case the problem would get worse. I was told at that time that that was the fault by the code reader man, but eventually it started after a fuel filter change and lots of expletives. As long as the car stays going, even with misfiring, I'm nervous to touch. My misfire is ever present, I would say, but you can't feel it all the time. As you cruise at 60, say, it goes along grand, but just feels a bit soft. Put the foot down and it responds. Decelerate and it's fine too. Just at that crossover point there's that 'softness'
I don't really expect a solution - I'm just vocalising to add to the knowledge base.
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