If i was you i would.
- Replace the leak pipes between the injectors. These are braided pipes of short lenegth running from each injector. Replace with new pipes. Cost £1.50 from motor factors.
- Replace diesel filter. This could be a source of air ingress. If not done for awhile, it wont harm a change either. Its the unit on the engine side by the air filter housing. Best way to do this and get a proper seal is.
1) Remove the 2 plastic clip diesel pipes (these are forward facing, one above other)
2) Unbolt (13mm spanner) the 2 bolts holding the primer pump and filter to the engine.
3) Remove the unit from the engine bay. U might need to move air filter housing to get it out.
4) Using a new filter (£4 in halfords with seals inc). Remove the old filter using a 10mm spanner on the single long bolt on top of the unit.
5) Pull apart, been carefull for diesel spillage.
6) Replace all seals with the correct ones inc in new filter, place together and re-bolt together. Re-fit in reverse.
7) Attach the bottom pipe ONLY to the unit when fitted back into engine bay.
8) Pump the primer pump by hand ontop of the filter, until fresh bubble free diesel comes thru the pipe which isnt connect.
9)Connect the pipe to top one once happen. Check seals for leaks.
10) Crank engine until starts. If engine fails to start, re-bleed filter, then remove pipe from fuel pump and keep priming until it comes through and refit. Then remove injector nuts with a 17mm until diesel comes through. *Probally wont need to do this step*
- New air filter - Again, if not serviced recently, it can help.
- Injector cleaner - clean out the system, u never know.
- Check injector bases for leaks. Most never leak, but ford suggest replacement at 100k. If yours dont leak, then dont bother replacing as they cost a fortune.
Also try www.fordmondeo.org for more help.
I had similar problem, fitted a new diesel filter and primer unit (£25 in total) with a new air filter (£20 but uprated sport type) and leak pipes (£1.50) and my car runs a dream now.
Air can get in the primer pump and cause problems, so i would replace filter and seals 1st. Then the pump if you believe its that.
Hope this helps.
J P Evans, February 2006
