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Just bought a 2.2 TDCi, possible problem?


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#1 Blue

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Posted 06 December 2009 - 04:06 PM

Hi guys,

After lots of looking around I finally got myself an 05 2.2 TDCi with 77K on the clock. The car has all the stamps in the book etc. and drives beautifully, very powerful and pulls like a train. So far so good. :D

However, I went to start the car this morning and it misfired terribly for a few seconds, there was a lot of smoke but it cleared once the engine settled down. I only drive it for a few yards to move it on the drive, when I restarted again an hour or two later there was still some smoke but it wasn't too bad.

When starting yesterday after it had only stood a short while there was no problem.

Is this something that can just happen as a TDCi quirk or do I have an issue?

Fuel economy on a fast motorway run home and with some town driving was 40mpg (actual) so not too bad, although I was hoping for more and was planning to change the MAF anyway.

Any advice appreciated!

#2 nathanharold1987

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Posted 06 December 2009 - 04:17 PM

It is quite common that the injectors leak very slowly into the cylinders when the car stands for a while (like overnight) and when its started in the morning there is excess diesel in the cylinders.

This causes a lumpy idle and smoking. Mine had the same symptoms except the smoking and it was air in the fuel filter. If it is smoking I suggest that its probably the injectors leaking.

This does not automatically indicate a problem. Many people on here have this issue and have just learnt to live with it
1992 Mercedes 190E 2.0 Petrol Auto
2010 Mazda 3 MPS 2.3 Turbo Petrol 260PS
2006 Mondeo Zetec 2.0 TDCi 130 - Remapped to 165bhp

#3 Blue

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Posted 06 December 2009 - 04:22 PM

Actually the only other bit that I forgot to mention was that the car ran lumpy at the first set of lights I stopped at, the revs were visibly going up and down at idle. Again, this cleared once warmed through. If this isn't indicative of a major problem then I'll just live with it! :)

I think I'll focus on sorting the MAF for now as it's bound to want replacing, I guess I can't easily blank the EGR off though due to it being a later model. :(

#4 nathanharold1987

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Posted 06 December 2009 - 04:35 PM

Depends. Does your EGR have an electronic sensor on the top? If it does then the engine managment light will stay on if you blank it off.

Take the EGR valve off and give it a good clean. I got my mondeo with 37k miles on it and it was manky. Also remove the inlet manifold and clean that also (the also get manky).

Your running problems may also be EGR related, the valve may be stuck open
1992 Mercedes 190E 2.0 Petrol Auto
2010 Mazda 3 MPS 2.3 Turbo Petrol 260PS
2006 Mondeo Zetec 2.0 TDCi 130 - Remapped to 165bhp

#5 Blue

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Posted 06 December 2009 - 04:49 PM

Erm, are there any pictures anywhere of what the different types of EGR look like? As mine is a facelift 2.2 I'm guessing it's Euro 4 and as such is incompatible with having the EGR blanked.

I think mine may actually be hidden under all of the engine cover!

#6 nathanharold1987

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Posted 06 December 2009 - 05:21 PM

Your EGR should be at the front right hand side of the Engine bay.

http://www.fordmonde...php?tid/782604/

That thread shows where it is and what it looks like. If yours is a Euro 4 facelift it will be the vacuum operated unit with sensor like mine.

You can blank it off, however the engine management light will stay on and unfortunately at this point there is no fix for this
1992 Mercedes 190E 2.0 Petrol Auto
2010 Mazda 3 MPS 2.3 Turbo Petrol 260PS
2006 Mondeo Zetec 2.0 TDCi 130 - Remapped to 165bhp

#7 nathanharold1987

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Posted 06 December 2009 - 05:29 PM

For the record, my mondeo is 2006 euro 4 and this is my EGR valve after 37000 miles.

http://i289.photobuc...87/DSC01174.jpg

http://i289.photobuc...87/DSC01176.jpg

As you can see, the airflow is quite restricted through there, and the valve can also get stuck open which results in poor starting and black smoke when starting and generally accelerating hard.

My inlet manifold was also in a right state so I cleaned the whole lot and noticed the car started better and got better MPG. I also noticed an improvement in performance.

I last cleaned it out at 45k miles, at 54500 miles now so will probs have another look mid 60,000
1992 Mercedes 190E 2.0 Petrol Auto
2010 Mazda 3 MPS 2.3 Turbo Petrol 260PS
2006 Mondeo Zetec 2.0 TDCi 130 - Remapped to 165bhp

#8 Blue

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Posted 06 December 2009 - 05:34 PM

Ah, thanks for that, I'll make it a priority to have the EGR cleaned out thoroughly then (think I'll watch whilst letting someone else do it the first time!) As I have noticed that I leave an extremely impressive plume of smoke when I accelerate hard it is likely that this is also part of the problem!

I'll see what difference a MAF, Manifold and EGR clean makes!

#9 SRH990

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Posted 06 December 2009 - 07:18 PM

My EGR was pretty much the same as Nathan's when I looked at it, I'd recently bought the car, a 2006 Euro 4 130 TDCi with 83k miles on the clock so this must have spent a lot of time on motorways to run up so many miles in 3 years. It's now clean but I've not looked at the manifold yet and the EGR blanking plate with 5mm hole is a bust.

I've got the eBay £50 diagnostic lead and this actually gives live date for EGR flow si I might experiment a bit with the hole size in the EGR blanking plate but even with a 5mm hole I still got sooty deposits on both sides of the blanking plate and already starting to coat the valve body, pity really as it definately ran better with it fitted.
Steve H

'06 Zetec TDCi 130 Euro IV, '04 TDCi 130 Euro IV

#10 Micky

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Posted 06 December 2009 - 11:12 PM

Problem with motorway running is that six speed box = 2k rpm at 80mph (ish) car seems to build up "clag" that clears when booted up to 3k or more.

Teflon coating needed for EGR and inlet manifold.