56plate TDCi Black smoke - but not the usual pipe. - Exhausts / Induction (Mk3 Mondeo) - TalkFord.com

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56plate TDCi Black smoke - but not the usual pipe.

tdci smoke performance

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9 replies to this topic

#1 M_J

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Posted 03 October 2019 - 11:29 AM

Hi Everyone

 

My first post here, I've read many so hopefully I'll provide enough info.

 

My Mondeo is suffering from quite reduced power below 2000 revs and, when under load and accelerating hard, masses of black smoke. There also seems to be smaller amounts of black smoke just generally running. Everything seems fine with high revs and long drives on the motor seem economical enough. It only just got through the MOT back in Feb, the dude had issues with the emissions.

 

History, It's been serviced by ford for the first 10yrs of its life, the last 2 my a local garage before I bought it then by me. I had an issue a year or so ago where it was very juddery around 1750 rpm, that turned out to be the big pipe below the EGR valve. I replaced that with a fancy silicone one and it's been fine. It did just over 60k in the first 10yrs, about 30k in the last 3.

 

So far I've taken the EGR valve off and cleaned that, wasn't too mucky, I've checked the pipe I replaced and that seems fine. I've also had a look around the engine bay, from above, to see if I can see any signs of dirt that could be from another split somewhere but can't see anything.

 

Recently, I've just done the service and replaced all filters, even though they have only just been replaced, in a bid to rule out.

 

There is also a slight high pitched noise, almost a whistle on acceleration, doesn't matter the starting revs, more noticeable when stationary but not too obvious.

 

I've read as many posts as I can and can't seem to find anything other than the pipe that I've already replaced and possibly drilling a hole in the turbo housing to spray Mr Muscle in there to clear the veins off - I've not done that yet as I'm contemplating taking it to Ford to ask them to diagnose and didn't want to confuse things.

 

Any help will be greatly appreciated!

 

Cheers

 

MJ

 

 



#2 DavieWeegie

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Posted 03 October 2019 - 12:05 PM

any of the boost hoses/pipes can split or pop off and you wont see much from the top end of the engine bay, their nearly all underneath so its a case of taking the undertrays off and checking each one to make sure their all secure with no splits, with you sayign theres a whistle this could be caused by a split hose.

 

you could also try blanking the egr with a blanking plate to rules out egr problems, even though its clean it may be sticking open which will cause black smoke and with you saying its happening just before 2000 revs this is usually when they egr will be opening and closing so best to blank it off to rule it out.


Performance Blue Mondeo ST TDCI 2005


#3 M_J

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Posted 03 October 2019 - 01:12 PM

any of the boost hoses/pipes can split or pop off and you wont see much from the top end of the engine bay, their nearly all underneath so its a case of taking the undertrays off and checking each one to make sure their all secure with no splits, with you sayign theres a whistle this could be caused by a split hose.

 

you could also try blanking the egr with a blanking plate to rules out egr problems, even though its clean it may be sticking open which will cause black smoke and with you saying its happening just before 2000 revs this is usually when they egr will be opening and closing so best to blank it off to rule it out.

 

Thanks DavieWeegie, I'll take the undertrays off and see what I can see.

 

To blank the egr valve:

  • where would a blanking plate be put?
  • Would it then require a reset of the ecu afterwards?
  • If there is no smoke with it blanked does that mean an egr fault?

Thanks again

 

MJ



#4 DavieWeegie

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Posted 03 October 2019 - 03:33 PM

the blanking plate goes in between the egr and the metal pipe that runs along the front of the engine, and yes if the smoke clears with the plate then it indicates an egr fault it will also not require an ecu reset.

 

if the engine is euro3 the engine management light wont illuminate, if its euro4 then the eml will come on, its then upto you if you want to leave the blank in place and just reset the light with a cheap hand held scanner or phone app each time it comes on. alot of us just leave the egr blanked off as the engine benefits from the cleaner air but some also notice the engine slightly noisier with it blanked.


Performance Blue Mondeo ST TDCI 2005


#5 ST56

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Posted 03 October 2019 - 04:16 PM

Hi

A small leak in the exhaust will cause the turbo to whistle but should not cause smoke. Plus as DW suggests in above post a cheap blanking plate will quickly confirm if EGR has started to fail and not close fully.

Peter
MK5 Mondeo 5 Door Hatch 210PS Titanium X Full Bodykit on 19" Y-Spoke Wheels.
Previously Mondeo MK3 2.2 ST Tdci. (ST56MON).

Previously Mondeo MK2 ST200.

Previously Sierra XR4x4.

Previously Escort XR3i, Capri, Sierra, Escorts RS2000, RS1600, Mexico & 1300GT.
.

#6 PURPLE_2L_LX

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Posted 04 October 2019 - 04:35 AM

My backbox fell off whilst on holiday and you could hear the turbo spooling up and

down which was an amusing whistle, funny at first buy annoying later.

 

Small 6inch (ish) pipe under the engine/gearbox can pop off. A lack of boost can cause

smoke. Seems the ECU doesnt compensate as much if you lose boost and overfuels.


MK4.5 TDCI 140 Business Estate.

 

MK3 FUSE INFO CLICK HERE ... FORD WIKI CLICK HERE .... FORD ETIS CLICK HERE

Adding your location may find someone local who could offer assistance.

F-Super, Bluetooth OBDII (ELM) and a MS509 scanners (test subjects required).

ForDiag now available to victims.


#7 M_J

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Posted 30 January 2020 - 12:58 PM

Thanks for the info folks and sorry for my huge delay in replying. I've done a video but having issue getting it up here...I think I've now found a way :) 

 

Basically, where I'm up to, I've disconnected the EGR valve electrical connector and the car runs like a dream no black smoke or anything, all the power is there too, seems great except the warning light has come one.

 

So I guess this means the valve is closing properly but potentially opening too much or there is an issue with the pipes to the right (as you look at it).

 

Video: https://photos.app.g...Gyng1W534XJenp6

Pic of underside: https://photos.app.g...wdLW55ugQuBrGAA

 

I've got a little endoscope type camera that I could poke down the pipes to see what's what but I suspect it would ruin it with gunk, could be good to get a look in tight spaces without dismantling though.

 

Any further assistance appreciated. Thanks again

 

MJ



#8 DavieWeegie

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Posted 30 January 2020 - 03:38 PM

blank it, buy a cheap and cheerfull autel maxiscan from ebay for £13 and reset the light each time it comes on, job done


Performance Blue Mondeo ST TDCI 2005


#9 nicam49

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Posted 31 January 2020 - 12:59 AM

Hmm, if your mot was in Feb, then that was before the new more stringent pass criterion for the smoke test, which was 3ppm (parts per million) After March, it was the figure on the vin plate, which in most cases is around half.. 1.5 ish ppm.. However, if the vin plate figure can't be read, (if for example, someone has unscrupulously made it illegible... then the mot station has to revert to the old pass limit of 3ppm...🤔 Would anyone stoop THAT low?
<p><p>nicam49 2002 Mondeo TDCi Ghia X Estate mk3 pre facelift Stardust Silver+Rust.[b] 308,000+miles, but been off the road since Nov 2019 after timing chain slipped during fuel pump transplant. Awaiting return of mojo

#10 PURPLE_2L_LX

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Posted 31 January 2020 - 02:08 AM

Nah nobody would do that its a pub fairly tale people tell you after they have downed

20 pints  :)

 

Alledgedly someone did that and tried to make it look like that box was blank from

the factory only for the MOT to show such a tiny number they wasted their time.

 

It would have flown through anyway. At least he seems to be looking after that one.

His previous experience with cars was to brag he had the newest car in the family

and then crash it within a week of purchase.


MK4.5 TDCI 140 Business Estate.

 

MK3 FUSE INFO CLICK HERE ... FORD WIKI CLICK HERE .... FORD ETIS CLICK HERE

Adding your location may find someone local who could offer assistance.

F-Super, Bluetooth OBDII (ELM) and a MS509 scanners (test subjects required).

ForDiag now available to victims.





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