Mongdeo TDCI woes

[phil_h_88]

Hi all,
I've not long chopped in my lovely Volvo S60 2.0T for a extremely boring Mondeo TDCI for the work run. I do a 70 mile round trip every day through the Cotswolds, so obviously lots of hills and inclines. I've recently noticed that when trying to get up some of the steeper hills, the car is really struggling - as in not getting any more than 30-40mph. (along with smoke plume and pretty bad vibration - but that's another matter). It feels really flat, I've tried dropping gears, shifting up - still chugging up and getting overtaken by 106s, Corsas and other . I never had a problem with my old car and I've never had a car, modern or not which struggles this much on a hill.

On flat ground it feels OK ( aside from comedy vibration under load) so I'm hoping it's not the turbocharger or anything major. I don't have much clue about diesels to be honest, so any ideas?

Cheers

[CNHSS1]

we had a similar issue on my wifes mondingo diseasel, turned out to be a splitting turbo hose. The hoses run from behind engine against bulkhead, under the engine and then upbetween engine and rad/intercooler.
the vibration under load was split opening and closing, very soon 'cured' itself by splitting hose properly.
Split wasnt visible or possible to feel air escaping when engine idling, only under load.

[HustleRussell]

CNHSS1 has got it in one, I suspect. I had the same thing. There's a possibility it's an injector or two, but boost hoses should certainly be your first port of call. The split hose will be releasing an oil must into the engine bay so it should be easyish to spot. The usual suspect is the intercooler to EGR/manifold hose which is close to the radiator and on the off-side.

[phil_h_88]

Thanks for your replies gents, I will be having a good look later on to see if I can spot and splits or holes. It would be a relief if that's all it was! Will report back with findings.

[vetrof]

I agree, sounds like front rubber hose. Might also be worth taking off the EGR valve and inlet manifold and giving them a good clean. When I bought my car (Mk3) inlet port to cyl 4 was about 40% blocked.

http://www.fordwiki.co.uk/index.php/EGR_Valve_and_...

[PaulKemp]

I had a split intercooler hose and it still went like a train with a noticeable power loss when the split opened on boost
Nowhere near as bad as you describe
I've cleaned out the EGR and the inlet manifold it made some difference but not that much
Have you changed the fuel filter, this can cause fuel delivery issues
Do you get the dreaded glow plug light flashing?
If so gird your loins for a big bill
I've just changed all 4 injectors £750

[phil_h_88]

Just gone out and popped the bonnet, lo and behold the large rubber hose going to the EGR has a big old split running down it, (about 3 inches long) First port of call will be replacing that then. I've had no flashing glowplug lights (yet!) so hopefully this will solve it. Cheers

[phil_h_88]

Update on this then, I removed the offending hose and patched the split with a hose repair kit then took it for a test drive. WOW! It pulls like a train, there's less smoke and the turbo spools much faster than before. It must have been losing a hell of a lot of boost as it now drives like a different car! Much, much faster and can accelerate and overtake with ease. Still have the persistent vibration under load problem but I will be sorting that in due course.

Thanks for the help gents

[Zad]

Always good to hear of a happy ending!

[PaulKemp]

The hose is £55 from Fords
eBay have a silicon replacement for £35
Your patch repair won't last long as the EGR gunk that blocks the inlet manifold will also soften the repair

[phil_h_88]

Yeah it's just a temp repair, the replacement hose is on order.