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ford mondeo IV 2008 1.8 TDCI FFBA misfire

Posted By cork_ie 6/4/2010 6:48:52 PM
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cork_ie
 Posted 6/4/2010 6:48:52 PM
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Hi all ,
I hope someone may have come across this problem and shed some light on the subject.

Car is a 2008 Mondeo 1.8 TDCI with FFBA Euro 4 engine. Engine has 35K Miles on the clock.
Injectors are Siemens piezo. Car starts easily and idles fine at all temperatures.
A serious misfire starts at 1200 RPM with a lot of smoke (especially under load) up to about 1800 RPM.Smoke is dark grey to black , puffy and smells like it has unburnt fuel from it too.
Once the revs hit about 2500 car runs OK and is off like a rocket.
Car spent months at main dealers who have washed their hands of the car. Car had accident damage at about 12K miles but no engine damage. They claim this voids any warranty which in my mind is BS.
There were no issues from 12K miles to 35K
I have done a lot of Common rails and never been beaten but this one is challenging!!

Dealer has :
Checked Dual Mass Flywheel = no problems
Swapped injectors with another car - no difference
Updated ECU to latest software
Returned car worse than what it was (according to customer).

I have:
Found no relevant DTC's at any stage
Blanked off EGR - no difference
Checked current waveform to each injector with PICO Scope at 900,1200,1800 ,2500 for each injector . Each injector seems to have same waveform.2 pilot injections & 1 main up to 1800 RPM ,1 pilot injection & 1 main at 2500. Intake is moderately clean and no sign of excessive fouling of EGR or intake.
MAP.MAF,Boost Press, Rail Press ,air and coolant temp all read normal and as expected
Checked that coding is correct for all injectors.
Carried out compression test & cylinder balance test with PICO Diagnostics suite . compression tests out perfectly equal in all 4 cylinders. Balance all OK at 900 RPM
At 1200 RPM Balance shows 2 cyls at 100%, one at about 90% and the fourth at 70% . Only problem is there is no way to determine which one is the 70%.

I am really at my wits end with this one and any help would be really appreciated
6/4/2010 8:34:40 PM by cork_ie
Angus
 Posted 6/4/2010 7:18:02 PM
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cork ie

What colour is the smoke?

.

cork_ie
 Posted 6/4/2010 7:26:28 PM
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Dark Grey to Black , puffy and smells like it has unburnt fuel from it too.

Very much like gross overfuelling or a complete compression failure on 1 cylinder
Angus
 Posted 6/4/2010 7:41:38 PM
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cork ie

Are you very sure that the EGR was totally blanked?  Dark smoke would sugget a lack of burnable airflow.

Have you, or anyone else, done a compression test?

Could any part of the intake path have internal damage, a foreign body, or be delaminating?

Can't find any useful data on that engine; but random thoughts:-

Has it got variable valve timing?

Has the cam-belt jumped a notch?

Has it got intake manifold runners?

Could it have a broken valvespring?

What fuel is in the tank?

.

6/4/2010 7:48:19 PM by Angus
cork_ie
 Posted 6/4/2010 8:08:56 PM
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Hi Angus
Thanks for your help
Are you very sure that the EGR was totally blanked? Dark smoke would suggest a lack of burnable airflow. Yes

Have you, or anyone else, done a compression test? Yes with PICO Diagnostics suite and cylinder balance test too.
Balance shows 2 cyls at 100%, one at about 90% and the fourth at 70% all at 1200 RPM . Only problem is there is no way to determine which one is the 70%

Could any part of the intake path have internal damage, a foreign body, or be delaminating? Why would that only cause an issue between 1200 & 1800 RPM?

Can't find any useful data on that engine; but random thoughts:-

Has it got variable valve timing? Don't think so

Has the cam-belt jumped a notch? I doubt it idle & top speed are perfect

Has it got intake manifold runners? I think so by why would they cause a misfire at 1200 -1800 RPM.

Could it have a broken valvespring? Possible but very unlikely to give this kind of symptom

What fuel is in the tank? Definitely 100% non bio diesel

Thanks anyway. Your suggestions are very welcome
6/4/2010 8:19:30 PM by cork_ie
Radnorman
 Posted 6/5/2010 2:18:22 AM
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cork_ie (04/06/2010)

I have:
Found no relevant DTC's at any stage    
Blanked off EGR - no difference

With which scanner are you working?

I would suggest returning the EGR to normal. If there is an issue with the EGR valve/system, sort it! 

I stand, to be corrected.

timodank
 Posted 6/5/2010 2:58:54 AM
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have you checked the air intake for leaks or restricted, are the turbo pipe weak causing them to collapse till boost presure opens it ?
Angus
 Posted 6/5/2010 10:20:40 AM
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Have you, or anyone else, done a compression test? Yes with PICO Diagnostics suite and cylinder balance test too.  Balance shows 2 cyls at 100%, one at about 90% and the fourth at 70% - all at 1200 RPM . Only problem is there is no way to determine which one is the 70%

Those figures alone are reason to do a proper compression test.

Could any part of the intake path have internal damage, a foreign body, or be delaminating? Why would that only cause an issue between 1200 & 1800 RPM?

As airflow increases before there is full boost pressure?

Has the cam-belt jumped a notch? I doubt it idle & top speed are perfect

The smooth-running correction function might make it less noticable - what are the correction figures?

Has it got intake manifold runners? I think so by why would they cause a misfire at 1200 -1800 RPM.

Maybe because they've broken up and are partly blocking one, or more ports?

Could it have a broken valvespring? Possible but very unlikely to give this kind of symptom. 

I wouldn't be too sure of that - valvesprings can do very funny things.  I wouldn't be ruling anything out at this early stage.





.

Andy-01
 Posted 6/5/2010 2:49:36 PM
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Questions, questions ???

Most important one, do you have, or can get access to an IDS ??

If so, I would like to know what the cylinder balance readings are on datalogger ?
It will display them within a range from 0.7 to 1.3 on each cylinder.
What's the MAP reading at key on, idle, and during the concern ?
What are the compression readings in BAR please ?

Angus
 Posted 6/5/2010 3:54:22 PM
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cork ie

Just a further thought; have you measured the return pressure from the injectors?

The return line/fuel cooler might have got kinked during jig repairs and has now blocked?

.


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