Ford Mondeo, 2007

Engine power loss and black smoke

Problem Description

Engine power loss and black smoke The technician describes an issue with a Ford Mondeo 1.8TDCi, model year 2007. The engine loses power, resulting in engine power loss and black smoke from the exhaust. The engine warning light also illuminates. The technician suspected a fault in the engine’s air-fuel mixture charging system but could not identify the cause.

Solution

1. The cause is air ingress in the intercooler outlet pipe due to a loose or cracked intake air temperature (IAT) sensor. For repair, you need a modified intercooler outlet pipe TC and a blind connector for the sensor, as well as ECM software upgrade.

2. Install the modified pipe and remove the intake air temperature (IAT) sensor, which is no longer needed. Secure the connector with a blind connector. Attach the IAT sensor connecting cable to the wiring harness. Reprogram the ECM with the modified software and clear the fault codes. Verify the repair with a test drive.

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