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[JamesV6CDX]

Evening everyone,

Wondered if anyone had any thoughts on this.

I have a 2010 Mondeo, 2.0 TDCi 6 speed, which I've covered 10k in, over the last year. Fantastic car, rapid, 55mpg, handles well. Not had a single problem. 79,000 miles, lots of history, and home serviced by me including 3k oil and filter changes.

Tonight, I went to go to Argos to collect something. Immediately upon pulling off the drive (cold engine) there was a constant, almighty diesel knock, at anything above idle. This lasted for the ten mile journey, although wasn't quite as bad by the time I arrived.

I then went to Halfords, and put in almost a litre of wynnes type extreme clean treatment. The tank was just dropping onto the red at this point. I then took a more scenic drive home, and gave it a proper Italian tuneup.

Upon arriving at home it sounded almost normal. I guess the test will be, what it does on the next cold start, but, any ideas?

I know the earlier mondeo's were plagued with injector issues, but having done some reading, it appears that the engine in my car is supposed to be a bulletproof Peugeot diesel.

No noticeable power loss, no smoke, no EML, running fine. Just noisy. It's definitely diesel knock, and the oil level is fine.

Any further ideas please chaps?

[Andy H]

I don't have any model specific knowledge but could it be a rattle from something else?

Dual Mass Flywheel (DMF)?

or maybe the alternator pulley? (SWMBO's Galaxy diesel suddenly started running really rough last year - you could feel each compression/firing stroke through the steering when parking. Turned out to be the over-run clutch in the alternator pulley. A simple fix once I worked what was wrong.)

[Doctor Gollum]

Flywheel would be my first thought too

[JamesV6CDX]

Flywheel would be my first thought too

Also crossed my mind, and as always I'm happy to be proven wrong...

 but... it's a profound diesel knock...  I recognise the sound of old from previous diesels, including automatics. Definitely a diesel knock, rather than anything mechanical, so to speak... 

I've heard loads of flywheels let go, and start to get worn, in works cars... this noise is a diesel injector 

[Doctor Gollum]

Duff injector should be readily identified at the fuel rail... touch the pipe to each injector and the duff one will feel very different.

Flywheel can also show up as a rhythmic thumping.

When cold, do you press the clutch before cranking?

[JamesV6CDX]

Cheers Al

I sure do press the clutch when starting. Old habit from the days of my 1993 405 diesel which wasn’t keen on starting in winter!

[Viral_Jim]

Does pressing the clutch on start help preserve the DMF, as opposed to just starting in neutral with the clutch out? If so I've learned something new today!

[omegod]

I used some free software called FORSCAN to recode injectors on a TDCI I had, handy for fitting new or used ones 

[JamesV6CDX]

Interestingly, it was absolutely fine when I Did a 20 mile run today....

[Shackeng]

My son has a very nice 51 or 52 plate TDCI ex-plod Mondeo. It has been standing unused for at least 6 years in his garage. (Don't ask me ). IIRC it cost about £400 for Ford to code the injectors back in the day. Fortunately it was never required.

[serek]

I used some free software called FORSCAN to recode injectors on a TDCI I had, handy for fitting new or used ones

I use ford scan on daily bases
Great tool

[serek]

I used some free software called FORSCAN to recode injectors on a TDCI I had, handy for fitting new or used ones

On 2.0 tdci siemens injectors no coding required
Only correcting