mondeo diesel down on power?

Glaucus · 24 Jan 2017 at 17:05

put my car through an mot last week (2004 ford mondeo 2.0tdci)
where to get it through emissions, they first used fuel cleaner then changed the EGR valve which got it though mot just. But since then it has no power, I mean pick up trucks out accelerate me. Took it back and they've changed the mapf senor free of charge. But that's all they can do, its still a dog to drive now. No error codes or lights, and they say that's all they can do and i'll have to pay to take it to a diesel specialist to get a diagnosis.

I cant see how changing an egr valve could destroy the performance like that, or what else they could have done to get it through emissions.

would welcome any ideas, suggestions or help, as I would have just scrapped the car if i knew this and got another beaten up heap with 12months on mot. now due to mot i cant afford to do that.

slick rick · 24 Jan 2017 at 17:08

Is the car equipped with a DPF?

Glaucus · 24 Jan 2017 at 17:10

a quick google suggests it does.

xs2man · 24 Jan 2017 at 17:10

slick rick said:
Is the car equipped with a DPF?

Not in 2004 surely?

slick rick · 24 Jan 2017 at 17:15

my parent's 2004 5 series has a DPF, I am not sure if it was required at the time though so the Mondeo may not. The DPF clogged on the 5 series and it had no guts at all, struggled to get over 3000rpm. Cleared it out and it went fine again.

Glaucus · 24 Jan 2017 at 17:16

slick rick said:
my parent's 2004 5 series has a DPF, I am not sure if it was required at the time though so the Mondeo may not. The DPF clogged on the 5 series and it had no guts at all, struggled to get over 3000rpm. Cleared it out and it went fine again.

would it clog in a day, that's the thing, the performance was fine before the mot. Although i know next to nothing about diesels.

slick rick · 24 Jan 2017 at 17:22

I doubt it would be the DPF (if the car even has one) if the issue developed so quickly. Is the EGR controlled by vacuum? If so a damaged vacuum hose could possibly prevent the EGR from actuating. If the EGR was changed just before the issue appeared then I guess that would be the place to start looking first.

Glaucus · 24 Jan 2017 at 17:41

whats the best way of checking this?
is a couple of quid blanking plate tell me if the issue is with the egr?

slick rick · 24 Jan 2017 at 17:52

If the EGR valve has a pipe attached to it I would try and follow the pipe along its length looking for cracks or splits and that it is properly connected at both ends. If the EGR has an electrical connector on it then it is not vacuum controlled.

If a blanking plate is only a couple of quid it could be worth a shot, it might put the engine light on but if it improves the drive then you will know it is an EGR fault.

Glaucus · 24 Jan 2017 at 17:54

thanks, ill see what i can see tomorrow.

slick rick · 24 Jan 2017 at 17:58

Also check the condition of the air intake pipe and turbo pipes, if they are not connected properly or have a tear in any of them that could cause an issue.

blueboy2001 · 24 Jan 2017 at 20:15

A TDCi shouldn't need anything to get it through emissions. They should barely register on an MOT smoke test if running correctly.

No DPF on a 2004, and it'll be Euro 3 so vacuum actuated EGR valve.

Most issues on the injection side will throw a code, so it's probably an intake problem or the vanes on the turbo have stuck and it's no producing much boost.

The hose which runs straight down out of the bottom of the EGR valve to the intercooler tends to split and it's not always easy to find - best way is get some to rev the engine whilst you run your hand along it. At this age the intercooler could have rotted through. Check the air filter as well.

Iamzod · 24 Jan 2017 at 20:18

I have the same year, same engine car, there is no DPF.

The pipe that comes up from the back of the radiator from the intercooler however is really prone to splitting on the inside of one of the top bends, that caused massive power loss on mine and made it quite smokey under full throttle.

It's the big pipe that goes into the bottom of the EGR.

Glaucus · 24 Jan 2017 at 20:21

thanks. it first got

mean absorption 3.06 fail

then after new egr 2.62 pass

limit was 3.0

as i said felt fine on power before mot and their egr fitting, afterwards struggling to keep up with pickups. especially noticable between 40-60mph.
So i would have thought it would be turbo, for it to devlope a fault that fast?

hopefully then whilst changing the valve maybe they bent the pipe and split it or something, then failed to find the issue, then just changed MAf to try and keep me compliant. not sure why they changed it as they said no error codes and have found nothing wrong.

a1ex2001 · 24 Jan 2017 at 20:33

Any more smoke than usual? Mine lost all get up and go when the egr to intercooler hose split should be easy to spot as all sorts or oily rubbish sprays comes out of it. Easy for them to split it when changing the egr as they go brittle with age my 04 mondo is on it's third! Also worth checking all the pipes feeding the turbo if they've split or not been reconnected right that would explain it.

Don't let the garage off easily changing an egr valve to pass an mot is no excuse for breaking your car if it needs a diesel specialist they can pay!

Glaucus · 24 Jan 2017 at 20:36

a1ex2001 said:
Any more smoke than usual? Mine lost all get up and go when the egr to intercooler hose split should be easy to spot as all sorts or oily rubbish sprays comes out of it. Easy for them to split it when changing the egr as they go brittle with age my 04 mondo is on it's third! Also worth checking all the pipes feeding the turbo if they've split or not been reconnected right that would explain it.

Don't let the garage off easily changing an egr valve to pass an mot is no excuse for breaking your car if it needs a diesel specialist they can pay!

i would say their is, but its hard to tell when driving, its always been pretty smokey at night when looking at other cars headlights through it.

and i really don't want to let them off, however I'm also kind of over a barrel as i am absolutely skint at the moment, I simply cant afford to take it to another garage to get a report made (assuming it is their fault, it would be some timing if it wasn't) other than that route, i'm not sure what i can do legally?

Finglonga · 25 Jan 2017 at 09:46

The old mans Focus was exactly the same, it had a small split in one of the pipes, it was as simple as that. Check them all to make sure they are all intact.

Cyber-Mav · 25 Jan 2017 at 15:49

had 2 mondeos now tdci down on power. both times it was split boost pipe. thats 2005 and 2009 mondeo

Richard_16v · 25 Jan 2017 at 17:28

Yep my money on boost pipe, my 2005 was down on power, removed ever to clean when I noticed split in pipe, taped up and noticed improvement so bought a new pipe, took about an hour to fit as I didn't have ramps and had to remove underbody

Foghorn Leghorn · 25 Jan 2017 at 18:52

Another vote for boost pipe that connects to the bottom of the egr. The garage would've disconnected this to change the egr, they've either not reconnected it properly or it's split (very common).