Ford Mondeo Mk4 1.8 TDCi (09 plate) vibration / misfire

[muran]

Hi all,

I have a Ford Mondeo 1.8 TDCi which I bought a couple of months back and has been running sweet.

The trouble started when I noticed a strong diesel smell from outside the car and in the cabin and also saw smoke coming from the bonnet. I lifted the bonnet to find diesel spilled all over the engine from the injector leak off pipe. Having secure the pipe back in place, I'm still getting a slight smell of diesel after use but the car runs well apart from one thing.

At around 1200 - 1400 revs in neutral and stationary I have a pretty noticeable shake / vibration through the entire car. As the revs pick up this dies a little but is still noticeable even at motorway speeds when driving.

I have had a mechanic take a look at the injectors, perform a leak off test, check the diesel spray pattern etc and he has said they all seem fine.

There is a video here which demonstrates the problem very well - this is exactly what I am seeing and in this case it was fixed with a replacement injector, even though they bench tested all ok.

So, I guess my question is - is this a common fault / symptom of injectors failing on this model and is it worth getting hold of a used injector to swap out with each in turn to try and narrow down the issue?

Any comments on where I can obtain an injector from at a decent price and does anyone know for sure of the injectors either do or don't need coding on replacement?

It has been suggested also that this could be a DMF problem but I'm not convinced as the gear changes are smooth, there is no noise as such and there is no variation whether the clutch is in or out at any speed. The clutch bites nicely at the bottom and there is no judder.

Thanks for any advice.