Autodata’s Technical Team share their fixes to common problems raised through Autodata’s technical helpline, available to all UK customers.
Lack of engine power and black smoke on a Ford Mondeo
FAULT:
We have a customer with a 2007 Ford Mondeo 1,8 TDCi who is reporting the faults outlined above. The MIL is also illuminated. We suspect something is at fault in the engine intake system, but cannot find the cause.
FIX:
The cause is an air ingress at the turbocharger (TC) intercooler outlet pipe, due to a detached or broken intake air temperature (IAT) sensor. To complete this repair, a modified TC intercooler outlet pipe and a dummy connector, as well as an ECM software upgrade will be required. Fit the modified TC intercooler outlet pipe (see Fig 1.1). The IAT sensor is no longer required. Disconnect the IAT sensor multi-plug (see Fig 1.2), then insulate it using the dummy connector. Secure the IAT sensor wiring harness to the engine wiring harness with a cable tie. Re-program the ECM with the modified software, then erase the trouble codes and carry out a road test to ensure the faults have been rectified.
