Mk3 mondeo issues

bigjimmyauk · 17 Jan 2021 at 22:28

Quick background 2.0 TDCI purchased at 100k and done 80k in 4/5 years since I purchased its had, new injectors,turbo,dmf and clutch and a few other cheaper bits.

Recently within the last few weeks its cutting out without warning it will either start straight back up or take anything from 10 seconds to 20 minutes to get going again. Its had a leak of test done and injectors are good, fuel filter been changed. Been on ford diagnostics which shows nothing wrong at all prior to the cut(basically drove around until it cut out)

At a complete loss now, 3 garages have said they wouldn't know where to start and I've already done/had done the tests they would do.

I'm hoping with it being a 15 year old car and being many members on here someone might have encountered a similar issue which could possibly give me a starting point to look at myself.

Bit of a crapper as its the daily driver for work. Not really keen on putting 400/500 down for a run around to potentially be in the same position again(my track history with cheap motors isn't good)

Long post i know thanks in advance

bigjimmyauk · 17 Jan 2021 at 22:39

watercooledman said:
Fuel pump ?

Nope no shavings in the fuel filter, pressure is good and all electronics came back fine. Its also a £1200 part on mine so I'm glad its ok.

bigjimmyauk · 17 Jan 2021 at 22:40

BUDFORCE said:
Crank shaft sensor.

Replaced 18 months ago. Still currently working even took it out to clean it.

bigjimmyauk · 17 Jan 2021 at 22:41

Terminal_Boy said:
You’ve had the fault codes read?

Yeah no fault codes at all :confused:

bigjimmyauk · 17 Jan 2021 at 22:55

Terminal_Boy said:
Nothing weird like the fuel tank/fuel cap breather being clogged and vacuum locking the fuel system?

Ooh now there's something I've not considered! Just looked on part diagram and it does have a breather directly on the tank. I'll have a look at this tomorrow.

bigjimmyauk · 17 Jan 2021 at 23:41

koooowweeee said:
You can have a failing pump but no signs of it. Not saying it's that tho. But sounds like it or could be a air leak

Usually 2 pumps. Don't think either would be that sort of money. Not even half that. The one in the tank will be cheap as chips

Seriously they aren't cheap new and reccomended not to ever find second hand one due to the large fitting cost of them. Need to take of timing chain and sprockets and all sorts apparently.

bigjimmyauk · 17 Jan 2021 at 23:44

Terminal_Boy said:
Nothing weird like the fuel tank/fuel cap breather being clogged and vacuum locking the fuel system?

Could I quickly test this by going for a short drive with the filler cap loose? Would it have the same effect do you know.

bigjimmyauk · 18 Jan 2021 at 11:34

Thanks all ill givenall these a look over today while I'm off.

bigjimmyauk · 18 Jan 2021 at 11:55

Terminal_Boy said:
I don’t see why not if the tank isn’t full. Just take it easy in the corners.

Just trying this now. When I opened the filler a massive amount of air was sucked in. A sound I've not normally noticed. You may be on to something with this

bigjimmyauk · 20 Jan 2021 at 01:34

On a spur if a moment decision and after much google work I decided to try replacing the cam sensor(even tho is tested ok) and up to now 60 miles with zero cut out. Keep your fingers crossed for me.

bigjimmyauk · 20 Jan 2021 at 14:09

Resident said:
Been running supermarket fuel in 2.2 mk3 for over 3 years/50k. Not a hint of an issue.

To the OP, get the fuel filter changed. Use either an oem or Bosch one.

If you change it yourself, make sure you fill the filter with fuel before connecting it all up else it'll airlock.

Gets done every year without fail or 12k whichever comes first. Its well looked after tbh

bigjimmyauk · 20 Jan 2021 at 14:15

Iamzod said:
We've had about 5 that were taxi's & only managed 40-80k on a set of injectors on mainly Morrisons fuel. They were also having the EGR's gunk up and one was on it's 3rd turbo by 500k miles

My personal one did over 260k on the original injectors on purely Shell (as it's at the end of my street), in fact when I stripped the car for parts as the mileage made it worth far less than the value of the parts I sold the Injectors on Ebay & the buyer never reported any issues. I only cleaned the EGR when I sold it, again still the original & relatively gunk free.

Turbo, still original, sold without issue, didn't even clean it.

Yeah I mean I'm on 180k I never knew really what happened the first 100k of its life but it does have a very good history with it. 80k injectors replaced, timing chain tensioner was done too. but I only use premium diesel as the only time i tried morrisons diesel the car sounded like crap. Every summer I completely strip out the EGR and inlet manifold and decoke them of soot and grease including polishing up the inlet ports. It passed its MOT in November with a minor of slight play in front wheel bearing and nothing else. I'm hoping I can make it through the next couple of mots as I did put just over 1k into it in 2018 on new turbo,clutch and DMF

Fingers crossed this £20 cam sensor seems to have solved my issues.

bigjimmyauk · 20 Jan 2021 at 22:18

Resident said:
Similar for me. My next service is due around June time and I'm gonna add gearbox oil (changed last at 104k) and brake fluid (will be just over 2 years)

This was a big issue on mine. Gears were feeling stiff and wouldn't engage very well. Went to a local indy to change the gearbox oil (at 160k) and he was like na mate dont need doing it won't fix it bla bla bla. Got him to change it anyway for £35 and its been spot on ever since. Not a job to do yourself mind as it needs to be pumped back in under pressure.

Seen one for sale recently with 465k on the clock with FSH so gives me hope it might last another year or two. Just a shame they seem to suffer electrical,injector and turbo problems long before anything ever happens with the engine. Also recently discovered it has footwell lights but the bulbs were missing