We Fixed Dads Mondeo?! (Vlog)

So as you will probably know dads been having some issues with his tdci mondeo.. Today we attempt to fix it! enjoy.
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Music - Hip Hop Rap Instrumental (Crying Over You) by Chris Morrow 4 / chris-morrow-3 Creative Commons - Attribution 3.0 Unported- CC BY 3.0 creativecommons....

[@scottwalker4050]

Hello mate. I have one of these engines in a fairly high state of tune and know them inside out. Due to its age. It isnt subject to the new mot laws and it should be fine. If the egr was as clogged as it seemed on youe vid. Then id say that the plastic intake manifold on the front as well as the ports may also be choked up wirb carbon. The intake is easy to removed and clean up so id deffo reccomend doing that These engines will always smoke a little bit as the cylinder head design isnt the best for airflow and they struggle to get air in Mine doesnt smpke as bad as this one does and as i said its at a fairly high state of tune featuring a hybrid turbocharger. No cat and the egr removed completely Anyway. Hope that helps. Hit me up sometime!

[@mikedive9934]

Scott Walker hi was reading through your comments and noticed you have hybrid turbo, have you had any problems ie injectors etc? because I thought of getting one for my mondeo st would be grateful for any advice thanks

[@adamtip-toptipper7232]

I’d say a split boost pipe somewhere, most likely the one that goes from intercooler to the egr valve (the rubber hose u took off the egr valve) there a common fault on these engines 👍🏻

[@searsmartin]

Smoke caused by an EGR only happens when they stick open and turbo boost is lost through it resulting in too much fuel to Vs the actual amount of air entering combustion chamber the other ever being stuck closed is actually good opposed to the opposite. Look for a boost pipe leak or check the condition of the turbo

[@honymonster30]

When I had my mk3 mondeo TDCI I just blanked the egr valve. As your dad's is a later one that would put the engine light on. If you didn't clean out the inlet manifold when you cleaned the egr it probably needs doing. Also check the boost pipe for cracks very common

[@TRC98]

I've seen many people blank their EGRs, what advantages do you get?

[@honymonster30]

@@TRC98 Basically reduces the soot build up in the intake. When I bought my MK3 Mondeo the Inlet manifold and boost pipe were full off black gunk blanking the egr valve prevents this happening. Once blanked the car ran a lot better and no more smoke. It was easy to do with mechanical egr valves not so easy on electric ones and unnecessary on petrol engines.

[@jamesward506]

Look for a split turbo/boost pipe, even a small split can cause issues. It’s happened a few times on mine and everytime you think something drastic has happened. Also you can buy blanks that completely shut/block the function of the egr, and it will reduce smoke and increase performance. Your egr was basically blanking itself off, which in theory should’ve helped more than anything, unless it was just stiff and operating erratically.

[@nocode1603]

Good to see a son helping his dad out nice one!

[@bensdrivewaygarage9014]

Sorry folks this is going to be a long one..... Ok I own a mondeo tdci and have done for 7 years, only once has it been to a garage, I've done all the work myself. So firstly for the purpose of testing I'd buy a blanking plate for the egr (£2) don't buy the one with the hole it as they defeat the point. I've blanked my egr about 2 years ago and can honestly say throughout the rev range even with headlights behind I've not seen no smoke although getting a tiny bit on start up due to injectors. Here's what I'd do in this order.. 1) sign up to a site I'm a member of (talkford) 2)blank that egr, easy and cheap 3) check all the boost pipes from the turbo for splits (as already mentioned the egr boost hose is a common one) 4) remove the inlet hose to the turbo and check the compressor wheel for excessive play (some is normal but only minimal) 5) start looking over to the injectors and get a leak off test done, not only will it be good content but it'll give you a good idea of a failing injector. Make sure servicing is upto date and only use good quality fuel filters such as Bosch, Mann or Delphi. As for the Mot, smoke test only applies to vehicles fitted with a dpf and mk3s are only fitted with a catalytic converter. Take your time with it I did notice it has some Diesel knock on idle which would tell you an injector is on its way out. Good luck and I'm enjoying the astra content

[@ajdmisc]

My 220 was in "slow mode" for a week and after cleaning the EGR and turbo. I then went talkford and straight away saw "split pipe" found the split on the inside corner (top side bend). So annoyed at myself for not checking the pipes first 😂

[@conorturton]

When I did the EGR valve on my MK3 also took off the inlet manifold. Most of the ports were well blocked with sludge to the point that those nearest the EGR valve were letting through maybe only 50% of the air they should be..

[@soperdiact838]

Any diesel before an MOT - keep it in low gear on an open road with high revs. After about 5 minutes you'll notice the smoke disappearing. All diesels have this issue. The soot wells up in the exhaust system as you're driving the car normally. Only high revving can clear it.

[@twerki78]

Check your air hoses for leaks. Esp the hose from the intercooler to the EGR. Look for oily deposits. Black smoke is caused by over fueling. The MAF will monitor the airflow into the engine, but for some reason there is too much fuel to air so smoke/soot is being produced. You can blank off the EGR valve, on your euro 4 it will most likely throw an error code and light the EML but the car will run fine/better and the exhaust will be less smokey and give a little better fuel economy but your car will emit more NOX. Blanking the EGR and having the EML on is now an MOT fail, it wasn't when I did this. I had my 05 plate 130bhp Mondeo from 8k miles are sold at 185K, it went on to do 230k before the next owner gave up on it. Best car I've owned.

[@garethmorris1431]

I had this engine in my Jag. It smoked a bit when accelerating. No more than your dads mondeo. As said by others, some millers diesel treatment and a thrash on a dual carriageway would work well. Can get Millers from Euros for cheap enough

[@cumbrianrider8903]

I’ve seen lots of those mondeos with split intake pipes which causes the symptoms you have, either the pipe that joins the egr from the intercooler or the pipe going into the intercooler on the passenger side, keep up the good work

[@BillyNoMates1974]

Run some diesel cleaner through the tank and a good thrash down the motorway in 4th gear for 20 miles at 70mph would sort that out

[@stevecree606]

I agree, half a bottle of Redex for diesel engines in with a full tank of diesel - get it up to normal operating tempreture then good thrash on the motorway then run as normal.

[@BillyNoMates1974]

Had to do it in the wife's Kia Sedona 2.9l CRDI. Failed MOT on smoke, advised a thrash down the motorway (after garage had put Redex in). back in garage 30 mins later all passed. Diesel's love to be worked so sitting at 3,000 rpm (in forth gear) for 20 miles is not killing the engine

[@johneaston4963]

Millers diesel treatment works well,

[@Parknest]

BG244 is the one to use but Redex is better than nothing.

[@stevecree606]

Women and Diesels are alike, a good thrashing now and again works wonders.

[@realtrucker9213]

You need to get the engine up to normal operating temp, put some injector cleaner through, Forté is best, it will help clean the injectors and help get rid of some of the deposits of soot, but remember that most of the soot you were seeing was what would be in the exhaust system, give it a good run, at least 30 mins in 3rd and 4th down the motorway and this will cure the smoking issue. Hope that helps.

[@jordanharvey3923]

MOT rules state, when reved to 3000rpm or half the max rpm if less on a non dpf vehicle, IF smoke is emmited (any colour) and is dense enough to not see through the a fail, from what I see coming out the Mondeo, no worries on my behalf, and I'm a fully qualified mechanic and MOT assistant 👍👍

[@patrickmcgivern9686]

Check the rubber pipe that runs from the bottom of the egr valve. It is a common cause of smoking on those Mondeo's when it splits. Check around the back of the hose...the split can sometimes be hard to see. That was the problem on my late 05 Mondeo 2 .0 tdci titanium. Changed it to a silicon pipe from eBay and solved the smoking problem ,It also helps to give the system a clear out every now and then by driving in low gear up a short incline / hill....with hhighbrevs. Not popular with the environmentalists but good for the Mondeo !

[@steve0680657]

That's the Turbo bearing gone. New turbo required. Oil is being boosted into the intake air then charged into the engine. Also change the air filter. Diesels make more soot the richer they run.

[@bensdrivewaygarage9014]

Whilst I understand why you'd say that but on the tdci engine so like mk6 and early mk7 transits same as the mondeo mk3. They all blast out thick black smoke under heavy load, the amount of smoke from this engine is actually really good considering it doesn't have an egr blanking plate fitted.

[@rhys6990]

I thought turbo too

[@steve0680657]

Could also be worth doing an oil change... Low saps A5/B5 5w30 could help along with a clean air filter.

[@Phrozen2]

There is a few very a common issues with the Mondeo - I had one! 1: The EGR to Intercooler Boost Pipe - Splits and causes boost leak which emits BLACK smoke under load (Most common issue - I've replaced 2!) 2: Valve Stem Oil Seals - Generally white / blue smoke on a cold startup. 3: Turbo Oil Seals - Causes white smoke permanently. First point I would check is the EGR to Intercooler Boost Pipe, if it's split you can pick up an aftermarket one for about £25.00

[@aidan1585]

How long do the EGR's last in them? (Mileage)

[@Phrozen2]

​@@aidan1585 Not entirely sure as I blanked it when I had it - Car is now on 140k and still running strong.

[@aidan1585]

@@Phrozen2 We have a 2003 Ford Transit 2.0 TDdi LWB H2, it has 125,000mi and the EGR valve is working absolutely fine, I was just curious about the TDCi models.

[@Phrozen2]

@@aidan1585 must be using decent fuel then lol! They're like tanks the TDCi engines are, that car never once let me down

[@TheFakeRussian]

In my experience of Mondeo's, they all tend to smoke a bit anyway due to turbo lag. I have an 06 estate and I gotta admit it ran me all the way over to within 20 miles of the Bulgarian/Turkish boarder without a hitch! Over 6,000 miles covered in a month. Of course now I'm back in the UK I have to: Replace both front shocks. Replace the brake lines front to back. Replace both hanging bars for the rear anti-roll bar. Replace and renew the seals on one rear caliper. Then I'll have to take it to be 4 wheel tracked! Oh! And in the last 2 days the battery failed! I'm starting to think the car hates the UK.

[@memyself6095]

I've got a 54 plate 2.0 tdci mondeo 150k clean as a whistle never seen any smoke from it

[@Mickusdickus123]

Have you checked the egr to intercooler hose for splits? A very common fault on these cars. Will cause smoke and a small power loss.

[@oskarbc7213]

If the EGR valve still doesn't work, have a look if the vacuum line is broken any where

[@stevenjones19-m8i]

Another job done,fixing the EGR valve,looks straight forward to fit.I always like these videos.

[@jakeroberts3874]

Turbo is shot bin it and put another one on it and clean the intercooler out and piping can use petrol like I do should be happy then diesels usually smoke a bit under acceleration be worth putting new air filter in as well and change the diesel filter

[@VSTV1993]

Try giving it a blast on the motorway for a good hour keeping the revs above 3k. If that fails maybe try getting it terracleaned

[@tazba5551]

Nice vid mate. I had the same problem with my jag x type which is the same engine as this. I replaced the egr but it was only a temporary fix as the smoking returned after a while. I then stripped the cars front, cleaned out the egr valve along with the inlet manifold. I also replaced the air filter. While putting it back togetherI fully blanked the egr valve with a blanking plate. 6 months later it still drives really well and it's no longer smoking. Worth a shot if you ever get the same problem again

[@malcolmyoung7866]

Worst thing for modern diesels are short journeys. High mileage diesels fitted with EGR's will have 'sooting up' regardless but the short journey lifestyle is the killer, especially with DPF fitted cars. EGR's aren't service items on dealer services so it's up to the 'owner' to sort this out. Cleaning is the minimum, once a year as minimum I would suggest, maybe another time(every six months or so) if short journey's are mostly done. An EGR delete will prevent sooting up of the entire inlet side of the engine. So long as the EML doesn't come on it will not be a MOT fail. EML's mainly indicate emissions issues and as no warning lights are allowed to remain lit after the engine is running any lights on is an instant fail. If the EGR is purely mechanical it shouldn't be an issue. if the EGR is monitored by an ECU and throws up a light the car won't pass an MOT. The EGR recirculates unburnt gases from the exhaust mainly but also carries a lot of soot and deposits from the combustion process. Unlike the DPF it doesn't have the same impact of carcinogenic particles so isn't as critical with regards the health of the general public. DPF's DO prevent the introduction of carcinogenic particles and should never be tampered with. Hence the large fines that will be applied if you are caught.

[@CarsExposed]

Great video James, I used to drive a Mondeo just like it, and they all smoke it’s quite normal and should pass the Mot !!!! 👍

[@adamwoodward2003]

Black diesel smoke usually means that the diesel is not burning properly in the cylinder. Bad air flow could be causing the diesel to smolder rather than fully burn resulting in a lot of unburnt diesel going down the exhaust and causing black smoke.

[@totalypeedoff]

Hi, skimmed through loads of comments, and NOT seen anyone mention the hoses from the inter cooler to the EGR.... Most common fault on mons and X-Types.....They split and cause thick black sooty exhaust and lack of boost. Check the hoses from the EGR back to the inter cooler for oil on these two hoses

[@horlixs]

I had a 1.9 tdci and was the same a bit smokey on throttle.. the engine sounds normal. They suffer with the auxiliary belt tensioner noise. I had mine done and its sounded great for 3 months then started chattering again so i left it after that

[@admiralalcatraz6080]

I have had the same issue with my 06 Mondeo 2.0 TDCI, changed the EGR, gave a it a good long run and good thrash and it cleared over a few day .....

[@neilobusk]

I miss fixin things with my dad.........

[@monkey2275]

oh buddy...

[@TommyGames97]

I wish my dad would fix things with me I usually have to do all car stuff my sec

[@garryhills8648]

Hiya James I have a mk7 transit mine was blowing a lot of white smoke I replaced the copper washers on the injectors now it's like a brand new van !! I hope you sort it!!

[@lesrogers7310]

Does this have a particulate filter? If it does and your dad does mainly short journeys it could well be blocked...

[@Kofi_Mensahs_BurnerAccount]

Les Rogers considering the year, maybe not.

[@xtc31]

mk3s didnt have one. they came out on the mk4s

[@bensdrivewaygarage9014]

They only have catalytic converters fitted on the mk3 tdci although I've heard of mondeo a around Europe having been fitted with dpfs from factory

[@gordonstewart586]

I had similar issues but after blanking off the EGR valve (35,000 miles ago) and cleaning out the inlet manifold I’ve had no problem. A year later the engine went into limp mode but I sent the electronic actuator away for repair and once refitted that sorted that. I’m now on 155,000 miles with no problems.

[@aidan1585]

10:02 - Any diesel with a DPF/diesel particulate filter (2008+ usually) should be crystal clear. If it's not, there's something wrong with the engine/dpf. What you are seeing is particulate matter, a slight bit amount (25mg/km - just about invisible) was permitted for Euro 4 (2005/2006-2008). When Euro 5 came out (2009-2014), NO particulate matter was allowed (0 mg/km - non-detectable and invisible with no smell/scent). The same goes for Euro 6. Those Mk3 Mondeos did *not* have DPFs, they had a *Diesel oxidation catalytic converter* (Also known as a NOx catalyst) and an *Exhaust gas recirculation system* and were certified for Euro 3 (2000-2003) and Euro 4 (2004-2007) but the Euro 3 and Euro 4 was designed with no particulate matter to leave the pipe.

[@taxidude]

Check the dog legged turbo hose just under the valve. A split will cause smoking. Also, if the pipe goes soft, the suction makes it crumple causing a flat spot on acceleration followed by smoke.

[@eefmercer5079]

Is it bossting correctly? Can you here air pressure when you put your foot down? I reckon split in boost pipe If not james its always good to find a freindly MOT tester 🚗

[@ady01553]

Mass Air Flow Sensor Meter Cleaner Spray + Diesel Fuel System Injector Cleaner + New Air Filter + New Fuel Filter.

[@mlight6275]

mine went into limp have done service, fitted new egr, intercooler to egr hose, yet obd shows no faults. engine revs through range but under load/ foot down no boost. any ideas ? no smoke.

[@Chriswales]

The new MOT rules for diesels are: No visible smoke if the car has a DPF. If the car hasn't got a DPF then it's the same smoke test as before. Since you've stopped the main source of the smoke it should clear its self over the next few weeks. Giving it a good boot full in 2nd & 3rd gears once warm is always a good idea at least once a week and certainly on the way to the MOT.

[@offbeatwarble]

Chris Wales it's not quite the same as before, prior to revision turbo and non turbo vehicles were at set levels on the smoke test, now it's done on the individual vehicle plated value (usually lower)

[@Chriswales]

Well you learn something everyday, didn't know VIN plates could have an emission limit. Just had a look and if there's no value on the plate then the old 2..5/3.0 limits are used for pre July 2008 cars.

[@markellis4229]

Very true

[@CraigThomas1983]

I had a mk3 tdci 130hp, I had the issue with the egr and cleaned it but discovered I needed to take off the inlet manifold and clean that as it was also blocked solid. You might also want to check the intercooler, check for oil residue which will point out a leak.

[@westcoast747]

Sounds like a traction engine! 💨💨

[@steverpcb]

Clean / replace the MAP sensor, one blob of muck on it and it causes black smoke, it's on top of a horizontal pipe on the egr side of the intercooler. While you are at it replace the egr vertical hose with a silicon one as they split !

[@Parknest]

I love the cheap fixes and it is still the way Ford intended. I hope it lasts. I've heard of poor quality aftermarket EGR valves failing in a relatively short space of time. That's why I fitted an OEM Delphi EGR valve on my Mk4 Astra. It was £60 well spent. I get a bit of smoke on my C4 Grand Picasso if I accelerate harshly and is only noticeable in the headlights of whoever happens to be behind me.

[@andrewsmall6568]

Should double the resale value of your car mate! :)

[@rimmersbryggeri]

I would check the turbo actuator and MAP sensor. The variable vane turbos are pretty good for being coked up and not working also.

[@BadAls19]

air fuel ratio might be messed up because of a blocked air filter ?? black smoke is unburnt diesel it might not be getting enough air to burn the fuel this helped on my dads old 2.0hdi although it still smokes a bit but noticeably less

[@robertpowell7672]

Hi James. I have exactly the same car. I have replaced the Injectors and the EGR valve (cheapie off ebay) same as you. The only time I get a little smoke now is when starting off with engine under load at a road junction. It is better when the engine is hot. No smoke then.

[@andrewmason8844]

It’s normal for an 06 mondo it should pass the mot as its not got a particulate filter on it

[@andrewmason8844]

That’s funny my 2000 vw transporter has just past an mot and it smokes slightly but not excessive the new rule only applies to cars with a particulate filter you will never stop an old diesel smoking slightly if they have excessive smoke then yes they will fail but as long as it’s not classed as excessive you are fine at the end of the day it’s all down to the individual mot inspector

[@andrewmason8844]

Kris Nicholson have you even read what I’ve written you’ve just made my point 06 mondeos tdci’s don’t have PDF’s so as long as smoke is not excessive it will be fine

[@andrewmason8844]

Kris Nicholson omg idiot

[@Oliver-fp4xf]

Kris Nicholson Yes. Tough guy.

[@Oliver-fp4xf]

Kris Nicholson 😂

[@grahamroberts696]

I would check the diesel pump timing there's a lot of diesel knock at 8:30 sounds like it's over fuelling

[@chr15b]

Won't be an issue for the MOT. Later cars (Which came with a DPF) will have issues with smoke though.

[@jakubsima3654]

check if there is oil in the intake hoses and intercooler, if there is oil then the turbo has bad seals and the engine consumes oil. but it could be injectors or injector nozzles

[@denisbouvard3658]

Hello did you change the hose below thé egr I have that problem on my mondeo and the hose was just broken I replace it with à silicone hose and it fix this problem Have a good day 😊

[@kiedelve11]

The common cause of the smoke upon low rpm but high throttle input is normally the turbo actuator they stick and burn out the electric motor remove it and free off the turbo vanes and see how you get on. It’s very common in my work

[@chrisosborne6896]

Try the rubber pipes leading to/from intercooler. Slightest split letting air in will cause these to smoke more then normal, check where the pipes bend. From experience that's the weakest point. Also as said by someone else, MK3 Mondeo diesels all smoke a bit especially under load.

[@markmillyard5868]

Have you thought about the fuel injector pump or even the turbo changer because it could one of those thee things some times with worn fuel injection pump that could be feeding more fuel then it’s necessary or the second thing it could be a sign at some stage the turbo could need to be looked at and lastly I would check and see if the air filter is okay.

[@pointiscrap]

mark millyard if fuel injector pump worn then lack of pressure had it with my first one the car will come to a stage when the ecu decides below threshold pressure and shut the engine down. get some bio fuel run through to clean all the gunk out of fuel system change fuel filter and recon injectors will drive like a new one! I run mine on 50:50 bio diesel mix mega smooth and quiet. bought it cheap rebuilt injectors did the old drill hole in turbo exhaust side to clean vanes out with Mr Muscle. egr clean regular oil changes and a good run to work 50mile round trip to keep her clean inside, last one died cos of short runs 3-4 miles to work just died with the black death.

[@660star]

You should also reset the EGR memory from the module.

[@farmerlukep159]

Got a 2.0 tdci mondeo. And its been for a mot on 3 and a half injectors. Passed on the emissions no problem. Smokes a bit under acceleration but nothing bad like. My egr was choked up like that. Just left it in some diesel for a hour and or freed the valve off and works fine. Just take it off every few months and clean it out but good apart from that. Best to send it for a mot and see what happens 👍

[@toby5710]

In the 1.8tdci you can just blank it and drive on! 👍

[@insidebyte8561]

Jeez it knocks like mad!

[@coops206]

InsideByte Thats the alternator drive belt tensioner. A common problem on these.

[@cardie9430]

All diesel mondeos knock like a 306dturbo in minus 20c haha

[@caraudiosolutions]

I was thinking the same thing.

[@peterllewellyn665]

Check the intercooler hose. The tiniest of holes can cause black smoke on acceleration. Had the same issue with my mk3 Mondeo. if still after that then its time to clean the turbo.

[@yivi309]

I had the same problem, too much black smoke. What I do is only disconnect the electrical wire. I drive with the check engine in the Dashboard, but the car runs very very well, and It is very powerful

[@electrickal1]

Black smoke is not being created by a stuck closed EGR, those parcels of s*it stick open and clog the inlet manifold with waxy soot creating a narrowing and reduction in air intake, the engine tries to compensate by over fuelling hence the black smoke. Clean everything on the inlet side with carb cleaner, block off the EGR valve with a blanking plate and if you can also bypass the ECU programme for EGR as they are the death of any diesel engine. (Sneaky how they got the EGR to report on these engines by comparing MAF and MAP sensor data, makes it tougher to blank it without it throwing the MIL on). And by the sounds of it you also have an exhaust leak, check the back box for rust. Mk3 Mondeos are bundles of trouble in general, power steering racks wearing at straight ahead position, turbo VVR's gumming up, EGR's failing, Aux belt tensioners falling apart, DMF's, injector coding, rust, depreciation, heated washer jets burning out as the relay sticks ON killing cruise control and AC, rear brake calipers sticking and leaking. Apart from they they were good to drive, quick and well behaved at speed.

[@blingking501]

I've got 2.2 Mondeo had it remapped and blew black smoke like a train. I cleaned egr valve and inlet manifold out, and bought k&n induction and theres no smoke at all now. There's white smoke on startup but I've heard that's normal for these engines.

[@rhyschristopher1661]

Give it a good bit of right foot just before the MOT and you`ll be fine.Mine failed on emissions so I done a 4 mile run up the motorway in 3rd at 300rpm,took it back for a retest and it flew through.

[@shaggytryhorn3461]

I had this problem with mine and it was three things 1) having bad diesel 2) worn out injectors and a stuck closed egr I would check it for codes first and try diesel cleaner

[@Falco45able]

White smoke unburnt diesel black over dieseling, is this after you fitted injectors if so did they have copper seating washers and did you fit them?

[@sibon4797]

Top job maybe just residue as might not been working for a while but easier to blank egr off never to worry about it again 👍🏻 and put millers diesel additive in the fuel tank on every fill up sorted mine out, also check your hoses for a split

[@DashDriver-z1r]

I personally think you messed up. A clean functioning egr did not need replacing as the car still smokes under load i fear its turbo seals and oil is be8mg forced in. I also Remember these engines being fussy to get running right and £30 eBay egr valve is most likely going to fail as that’s way too cheap. Finally you should take it to a garage with a gas Analyzer and find out what’s coming out to help find the fault.

[@DashDriver-z1r]

Also it sounds off although it’s been a few years since I drove that shape tdci Mondeo.

[@AlexPriceAP]

Lee2709 Nah he's too busy crying on any EGR comments about air pollution blanking them off the big fanny 😂

[@matthewellis9885]

It wasn't functioning though? If you'd watched the video and listened you would've seen that the valve was seized meaning the egr would not open...

[@Roberto9696-q7s]

Could be the turbo. I would leave it as is. It's from 2006, if it's still driving ok, I would not even bother

[@mikecooper7816]

Sounds like the duel mass flywheel had it on a Peugeot 407 new solid flywheel and clutch.No problems

[@bbqnw30]

I have the same engine and it was 2 years (2004) older than you dad's car with same black smoke when I had my MOT in July which coincide with the new MOT law and it passed. I may need to look at my EGR as well to see if it needs cleaning or replacing as when I talked to my local garage they said that it is normal to a Mondeo to having that smoke. They just suggested to drive the car on high rev once every week.

[@robbie6707]

If it helps, I had to get a new exhaust backbox fitted to my Mondeo Diesel, the car used to puff out black smoke on acceleration but the new box has significantly reduced that.

[@ausnic83]

If the EGR was gunked up then the black plastic inlet manifold will be full of gunk too. maybe inspect and then clean/replace?

[@TheSavageGarage]

Ian Austin you didn't watch the last Mondeo video did you 😬

[@TrackAndBeyond]

Sounds like it has a bit of a miss fire under load, I have a 05 2.0 tdi 130 mondeo, have ahad to replace injectors twice, I have deleted my EGR with no smoke at all. Perhaps some kind of fuel cleaner might help, I’d definilty replace the fuel filter if that hasn’t been changed recently as that could be a suspect

[@kirwanjohn101]

Should you not have reset the EGR valve setting with a diagnostic tool when you changed the valve ?

[@timstinson1]

Try liqui moly diesel purge... great reviews on Amazon.. for a few quid worth ruling out expensive injectors...

[@cardude5323]

Clean the map sensor. Usually completely chocked yp with carbon. Also maf sensor a clean

[@LA-ph6hh]

Car Dude good point, I went to Maplins got some electrical cleaner, worked a treat, just spray it on, you want to avoid touching the fine wires with anything

[@steverpcb]

Correct, it's the MAP sensor, one blob on it and you get the black smoke :)

[@mack1609]

I used to have mrk3. Cleaned egr didn't work for me. Then removed the inlet manifold which was sooted up, all was OK for a while then just blanked egr and car was much improved

[@bigjimmyauk4595]

To be honest that just looks like soot accumulation. I've had mine for 4 years same engine and same year. Have you taken off the inlet manifold and cleaned it out and also cleaned out the intake ports with a dremel and brush. The car will be difficult to start afterwards but it does wonders for performance and cleanliness. Also it might be worth removing and back flushing the cat it's only a basic one and van be flushed with a hose. Keeping these engines running nice is all about keeping everything clean and tidy from intake to exhaust. Is the car using oil? And have you had the injectors checked

[@markaguy1626]

I see u have changed the egr valve but not take off the plastic intake cover to clean as it be clogged up with your valve holes but the problem u r have I had to with black smoke and engine sound like a bag or hammers the problem on my jaguar 2.0 x type with same engine was FUEL PUMP PRESSURE CONTROL REGULATOR VALVE SOLENOID

[@davesteward639]

I’ve got same car and been cleaning out the egr with carb cleaner. But I never tested the spring to see if it moves . My coil light comes on if I put my foot down then I lose turbo function. I might have to get a new egr bit .

[@eldodos83]

Those smoke a bit anyway those engines, a good hard run (italian tune up) might clear it a bit after stuck egr. Sounds like harmonic bottom pulley or tensioner making a bit of noise on it too at the minute

[@shaunhenry1614]

mine smokes like hell, been sat in a garage for 3 years un used as i couldnt find the problem with it but it had the same as yours, you'd rev it over 3000 rpm ish and you would get a coil light and it would die, so when i get round to it ill have to chabge thw EGR and do a leak off test, never bothered last time since the bodywork is wrecked, but for all the years i drove (and was driven in it) it was never ever ragged hard (owned by my grandad) and even then it smoked a lot, typical ford 2 litre duratorq

[@andykersey4210]

Try Forte Diesel additive. My MOT testing station swears by it. Don't follow directions on the bottle, just add to a quarter tank of diesel and do an "italian Tune up " i.e. lots of 4000rpm to blow the carbon out of the engine through the exhaust

[@Rob-zd2be]

What is the 2.0-litre engine like? Compared to your 2.2. As I am thinking of looking at one, just not sure about which engine would be best.

[@bobsmart2110]

The EGR valve opeñs on the phermostat common of it blocking the valve no lubricant no problem on ocations get the engine on working temp and put about half a pint of water yes water down the intake not the air filter ?now I have a 1.9sdi skoda fabia I do this to it ?last year's emissions were 014this year007you may ask the car has done more mles yet emissions gone down this is what water does to the cabin deposits in the engine ?I have done this for years on my cars even petrol try it

[@wirdy1]

I know you put Injectors in, but there are some dodgy 'refurbished' ones out there on ebay. I got mine refurbished at a Delphi approved workshop and they've been fine. Got diesel clatter and smoke just like yours before they were changed & I also had the hp pump breaking up internally so I replaced that & flushed fuel lines too. Doing the job again, I would buy new internals for the Injectors (valve & nozzles) and refurb them myself, I've since taken an old Delphi injector apart & it's not that difficult and Delphi parts are available online.

[@susantriscott7144]

check all the turbo plumbing etc. make sure its in good order and no leaks.

[@beznazwisk4851]

black smoke can be determined by turbine ailments, or air and intake system leaks, my mondeo has broken the EGR pipe, the car did not have the right mixture

[@BMW24]

I had the same thing changed egr still no better so cleaned out my turbo with mr muscle as seen on here and it worked a treat

[@grantfryer407]

same probs with my xtype got it all sorted then 2wks later car stopped dead on way home from werk..turned out fuel pump and injectors went..expensive night mare mondeo engine

[@granjerolunabrillo1487]

you should really get a diag tool so you can read fords live data and trigger as well as see the position of your egr valve, would be worth looking at your dads dpf on the mondeo also before the MOT. loving your vids mate when I don't have time of the funds to do things myself I just feel the need to watch others do it plus the misses prefers it because its cheaper lol, well unless she wants something doing on her motor haha. Andrew Moon.

[@dinosejdic3938]

I had the same problem, the hose from the intercooler was broken.The ecu did not register, and the mixture was bad.

[@hughjarse4627]

Am I right in thinking you have done injectors without the pump? Chances are your pumps breaking up and your injectors are going again, all Tdci fords are shite

[@sneekylinux]

Have just had to replace some intercooler pipes on on one of ours, really cheap fix even for a VW, but run some cleaner through it and give it a blast and that should cure it to be honest mate..

[@C1AE86]

also check for split boost pipes can cause black smoke from exhaust

[@simonparkinson1053]

Lot of chatter at idle, possibly alternator clutch pulley. Smoke issue you need to check live data if possible, look for desired and actual MAF readings and EGR command and feedback. Boost leak will cause excessive EGR because the logic says open up the EGR valve until the measured fresh air is reduced to just the amount needed for a clean burn. But with a leak a lot of that measured air never reaches the intake, but the EGR is still commanded for what's measured, removing too much oxygen and causing sooty burn. But.... You had a **circuit low** fault code. That's electrical rather than mechanical, so there could also be a broken wire back from the EGR valve, check for whether that code cleared and hasn't returned. Circuit low usually means the ECU is seeing a voltage lower than what is considered normal operational range, for example 0.5 to 4.5V.

[@Dubmegredborg]

On my last Mot, which i almost failed due to emissions, my mechanic told me to get the engine upto running tempreture and stick a water hose into the exhaust whilst revving the engine. Didnt try it out as he gave me a pass anyway

[@cmagennis927]

White smoke would be turbo issues and black smoke would be unburnt diesel (injectors)