2006 Mondeo Diesel in Limp Mode!

[Fury RS]

Hi, my best mate has owned a 1 owner 70,000 mls 2006 56 plate 2 litre diesel Mondeo Ghia for the past 6 months without a problem until the last 2 weeks. The car is fine for a while then loses most of it's power and goes into limp mode. The car has been at two different garages so far who thought they could sort the problem out but still to no avail and the cost is getting a bit silly now. So far; brand new injectors, fuel tank emptied and cleaned, fuel pump checked (ok) and new valve fitted to that and new fuel filters, new glow plugs and a second hand low mileage ECU (tested).
Turbo actuator maybe?
Any suggestions would be most welcome thanks...

[S0 What]

What do the fault codes say (or said)?
Personly i would have gone to a diesel specialist first and deffo when the first changes never worked, there's whole lot more items check and change before fitting a grands (ish) worth of new injectors, were they recoded to the ECU? and was the new ECU coded to the engine sensors/injectors ect? sorry but without decent info we are just pissing in the wind (as it sounds were the garages) some garages need to know when to pass on work to a specialist rather than spend the customers money.
Could be overboosting and sending it into LOS but really somone should have run a live data set and analysed it if there were no fault codes, has the EGR been checked/cleaned, if VV turbo is it free to move or is it gummed up with shight? are the cam and crank sensors in phase?

Edited by S0 What on Thursday 25th December 21:09

[Fury RS]

Supposedly cleared the original fault codes before the new ECU was fitted and yes the car was sent to Ford for the replacement ECU to be coded to the car but still going into Limp mode?
Thank you for your time to reply, I will present him with what you have said so he can give it to this so called Indy specialist.

[winshent]

Take off the arm that adjusts the vanes in the turbo and manually work it loose.

Could be the turbo is clogged and the actuator is struggling to adjust the vanes.

Have a look at this thread

http://www.pistonheads.com/GASSING/topic.asp?h=0&a...

Edited by winshent on Sunday 28th December 18:36

[camelot1971]

EGR would be the first place I would look. I've had 3 in my Mondeo (55 plate, 185k); first symptoms are dropping into limp mode and fine after a restart.

[Fury RS]

Thanks for the replies, will print these off and show them to the Tech at the garage this friday.

[Supercell]

Check for split turbo pipes, it's a common fault which soots up the turbo eventually.

[NooBish AbbZ]

we had this problem when using Tesco fuel. Changed to Shell along with all the other stuff, filters etc. and ran fine after that.

[Fury RS]

Update on my mates Mondeo; Sorted at last, a vacuum test was done on the fuel tank, found a plastic quality control tag had come off the fuel float and was getting sucked up whilst accelerating and was causing a blockage at the tank outlet! Surprised me abit when he said they had supposed to have emptied and cleaned the tank prior. Is this normal practice to have a tag on a part in a fuelling area???